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Volvo Penta Md11c D Md17c D Workshop Manual



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Workshop Manual        A
        Engine unit   2(0)




        MD11C, D, MD17C, D
                                                        Contents

Safety precautions ............................................................................................................. 2
General Information .......................................................................................................... 5
Repair instructions ............................................................................................................ 6
Component guide .............................................................................................................. 8

DISMANTLING
Cylinder head ..................................................................................................................... 10
Cylinder liner ...................................................................................................................... 11
Pistons, con-rods .............................................................................................................. 11
Timing gear ........................................................................................................................ 12
Flywheel ............................................................................................................................. 13
Crankshaft ......................................................................................................................... 14
Camshaft ........................................................................................................................... 14

OVERHAULING
Dismantling cylinder head ................................................................................................. 15
Cleaning, inspection .......................................................................................................... 15
Valve guides ...................................................................................................................... 15
Valve seats ........................................................................................................................ 16
Valves ................................................................................................................................ 16
Valve springs ..................................................................................................................... 16
Rocker mechanism ........................................................................................................... 16
Valve tappets .................................................................................................................... 16
Injector sleeve ................................................................................................................... 17
Injector ............................................................................................................................... 17
Assembling cylinder head ................................................................................................. 18
Cleaning, checking crankcase .......................................................................................... 18
Replacing main bearings ................................................................................................... 18
Centrifugal governor .......................................................................................................... 19
Pistons, liners .................................................................................................................... 19
Connecting rods ................................................................................................................. 20
Crankshaft ......................................................................................................................... 20
Camshaft ........................................................................................................................... 20
Oil pump ............................................................................................................................ 20
Feed pump ......................................................................................................................... 21
Thermostat ........................................................................................................................ 21
Sea water pump ................................................................................................................. 21
Hand start .......................................................................................................................... 23

ASSEMBLING
Crankshaft ......................................................................................................................... 24
Flywheel ............................................................................................................................. 25
Timing gear ........................................................................................................................ 25
Cylinders, cylinder liners ................................................................................................... 27
Pistons and liners .............................................................................................................. 28
Cylinder head ..................................................................................................................... 29
Adjusting valve clearance ................................................................................................. 30
Injection pump ................................................................................................................... 31
Checking control rod travel ............................................................................................... 32
Venting the fuel system .................................................................................................... 33
Checking injections angle ................................................................................................. 34
Adjusting engine speed ..................................................................................................... 34

Electrical system ............................................................................................................. 35
Wiring diagram ................................................................................................................ 35
Fault finding chart ........................................................................................................... 36
Special tools .................................................................................................................... 37
Technical data .................................................................................................................. 39
Cooling system, diagrammatic sketch ......................................................................... 43



                                                                                                                                              1
Safety Precautions
Introduction
                                                           Check that the warning or information decals on
This Workshop Manual contains technical data, de-
                                                           the product are always clearly visible. Replace
scriptions and repair instructions for Volvo Penta
                                                           decals that have been damaged or painted
products or product versions contained in the con-
                                                           over.
tents list. Ensure that the correct workshop literature
is being used.
Read the safety information and the Workshop
Manual "General Information" and "Repair In-               Never use start spray or similar to start the en-
structions" carefully before starting work.                gine. The starter element may cause an explo-
                                                           sion in the inlet manifold. Danger of personal in-
                                                           jury.
Important
In this book and on the engine you will find the follow-
ing special warning symbols.
                                                           Avoid opening the filler cap for engine coolant
      WARNING! If these instructions are not fol-          system (freshwater cooled engines) when the
      lowed there is a danger of personal injury, ex-      engine is still hot. Steam or hot coolant can
      tensive damage to the product or serious me-         spray out. Open the coolant filler cap carefully
      chanical malfunction.                                and slowly to release pressure before removing
                                                           the cap completely. Take great care if a cock,
      IMPORTANT! Used to draw your attention to            plug or engine coolant line must be removed
      something that can cause damage, product             from a hot engine. It is difficult to anticipate in
      malfunction or damage to property.                   which direction steam or hot coolant can spray
                                                           out.
NOTE! Used to draw your attention to important infor
      mation that will facilitate work or operations.

                                                           Hot oil can cause burns. Avoid skin contact
Below is a summary of the risks and safety precau-         with hot oil. Ensure that the lubrication system
tions you should always observe or carry out when          is not under pressure before commencing work
operating or servicing the engine.                         on it. Never start or operate the engine with the
                                                           oil filler cap removed, otherwise oil could be
      Immobilize the engine by turning off the power       ejected.
      supply to the engine at the main switch (switch-
      es) and lock it (them) in the OFF position before
      starting work. Set up a warning notice at the en-
      gine control point or helm.                          Stop the engine and close the sea cock before
                                                           carrying out operations on the engine cooling
      Generally, all servicing should be carried out       system.
      with the engine switched off. Some work (carry-
      ing out certain adjustments for example) re-
      quires the engine to be running. Approaching a
      running engine is dangerous. Loose clothing or       Only start the engine in a well-ventilated area. If
      long hair can fasten in rotating parts and cause     operating the engine in an enclosed space, en-
      serious personal injury.                             sure that exhaust gases and crankcase ventila-
      If working in proximity to a running engine, care-   tion emissions are ventilated out of the working
      less movements or a dropped tool can result in       area.
      personal injury. Avoid burns. Take precautions
      to avoid hot surfaces (exhausts, turbochargers,
      charge air pipes and starter elements etc.) and
      liquids in supply lines and hoses when the en-       Always use protective goggles where there is a
      gine is running or has been turned off immedi-       danger of pieces of metal, sparks from grinding,
      ately prior to starting work on it. Reinstall all    acid or other chemicals being thrown into your
      protective parts removed during service opera-       eyes. Your eyes are very sensitive, injury can
      tions before starting the engine.                    lead to loss of sight!




2
Avoid skin contact with oil. Long-term or repeat-    Never allow a naked flame or electric sparks
ed contact with oil can remove the natural oils      near the batteries. Never smoke in proximity to
from your skin. The result can be irritation, dry    the batteries. The batteries give off hydrogen
skin, eczema and other skin problems. Used oil       gas during charging which when mixed with air
is more dangerous to health than new oil. Use        can form an explosive gas - oxyhydrogen. This
protective gloves and avoid using oil-soaked         gas is easily ignited and highly volatile. Incor-
clothes and rags. Wash regularly, especially be-     rect connection of the battery can cause a
fore meals. Use the correct barrier cream to         spark which is sufficient to cause an explosion
prevent dry skin and to make cleaning your skin      with resulting damage. Do not disturb battery
easier.                                              connections when starting the engine (spark
                                                     risk) and do not lean over batteries.
Most chemicals used in products (engine and
transmission oils, glycol, petrol and diesel oil)    Never mix up the positive and negative battery
and workshop chemicals (solvents and paints)         terminals when installing. Incorrect installation
are hazardous to health Read the instructions        can result in serious damage to electrical equip-
on the product packaging carefully! Always fol-      ment. Refer to wiring diagrams.
low safety instructions (using breathing appar-
atus, protective goggles and gloves for ex-          Always use protective goggles when charging
ample). Ensure that other personnel are not          and handling batteries. The battery electrolyte
unwittingly exposed to hazardous substances          contains extremely corrosive sulfuric acid. If
(by breathing them in for example). Ensure that      this comes into contact with the skin, wash im-
ventilation is good. Handle used and excess          mediately with soap and plenty of water. If bat-
chemicals according to instructions.                 tery acid comes into contact with the eyes, im-
                                                     mediately flush with copious amounts of water
All fuels and many chemicals are inflammable.        and obtain medical assistance.
Ensure that a naked flame or sparks cannot ig-
nite fuel or chemicals. Combined with air in cer-    Turn off the engine and turn off power at main
tain ratios, petrol, some solvents and hydrogen      switch(es) before carrying out work on the elec-
from batteries are easily inflammable and explo-     trical system.
sive. Smoking is prohibited! Ensure that ventila-
tion is good and that the necessary safety pre-      Use the lifting eyes mounted on the engine/re-
cautions have been taken before carrying out         verse gear when lifting the drive unit.
welding or grinding work. Always have a fire ex-     Always check that lifting equipment is in good
tinguisher to hand in the workplace.                 condition and has sufficient load capacity to lift
                                                     the engine (engine weight including reverse gear
Store oil and fuel-soaked rags and fuel and oil      and any extra equipment installed).
filters safely. In certain conditions oil-soaked
rags can spontaneously ignite. Used fuel and oil     To ensure safe handling and to avoid damaging
filters are environmentally dangerous waste and      engine components on top of the engine, use a
must be deposited at an approved site for de-        lifting beam to raise the engine. All chains and
struction together with used lubricating oil, con-   cables should run parallel to each other and as
taminated fuel, paint remnants, solvent, de-         perpendicular as possible in relation to the top
greasing agents and waste from washing parts.        of the engine.

                                                     If extra equipment is installed on the engine al-
                                                     tering its center of gravity, a special lifting de-
                                                     vice is required to achieve the correct balance
                                                     for safe handling.

                                                     Never carry out work on an engine suspended
                                                     on a hoist.




                                                                                                           3
    Never remove heavy components alone, even          Always use fuels recommended by Volvo Pen-
    where secure lifting equipment such as secured     ta. Refer to the Instruction Book. The use of
    blocks are being used. Even where lifting equip-   lower quality fuels can damage the engine. On
    ment is being used it is best to carry out the     a diesel engine poor quality fuel can cause the
    work with two people; one to operate the lifting   control rod to seize and the engine to overrev
    equipment and the other to ensure that compo-      with the resulting risk of damage to the engine
    nents are not trapped and damaged when being       and personal injury. Poor fuel quality can also
    lifted. When working on-board ensure that there    lead to higher maintenance costs.
    is sufficient space to remove components with-
    out danger of injury or damage.

    Components in the electrical system, ignition
    system (gasoline engines) and fuel system on
    Volvo Penta products are designed and con-
    structed to minimize the risk of fire and explo-
    sion. The engine must not be run in areas
    where there are explosive materials.




4
General information
About the workshop manual
This workshop manual contains technical specifica-
tion, descriptions and instructions for repairing the
standard versions of the following engines MD11C, D,
MD17C, D. The workshop manual displays the opera-
tions carried out on any of the engines above. As a
result the illustrations and pictures in the manual that
show certain parts on the engines, do not in some
cases apply to all the engines listed above. However
the repair and service operations described are the
same in all essential details. Where they are not the
same this is stated in the manual and where the dif-
ference is considerable the operations are described
separately. Engine designations and numbers are
given on the number plate (See page 9). The engine
designation and number should be given in all corre-
spondence about the engine.
This Workshop Manual has been developed primarily
for Volvo Penta service workshops and qualified per-
sonnel. Persons using this book are assumed to have
a grounding in marine drive systems and be able to
carry out related mechanical and electrical work.
Volvo Penta is continuously developing their prod-
ucts. We therefore reserve the right to make changes.
All the information contained in this book is based on
product data available at the time of going to print.
Any essential changes or modifications introduced
into production or updated or revised service methods
introduced after the date of publication will be pro-
vided in the form of Service Bulletins.



Replacement parts
Replacement parts for electrical and fuel systems are
subject to statutory requirements (US Coast Guard
Safety Regulations for example). Volvo Penta Genu-
ine parts meet these requirements. Any type of dam-
age which results from the use of non-original Volvo
Penta replacement parts for the product will not be
covered under any warranty provided by Volvo Penta.




                                                           5
Repair instructions
The working methods described in the Service Man-
                                                           Our joint responsibility
ual apply to work carried out in a workshop. The en-
gine has been removed from the boat and is installed       Each engine consists of many connected systems
in an engine fixture. Unless otherwise stated recondi-     and components. If a component deviates from its
tioning work which can be carried out with the engine      technical specification the environmental impact of an
in place follows the same working method.                  otherwise good engine may be increased significant-
Warning symbols occurring in the Workshop Manual           ly. It is therefore vital that wear tolerances are main-
(for their meaning see Safety information)                 tained, that systems that can be adjusted are adjust-
                                                           ed properly and that Volvo Penta Genuine Parts as
      WARNING!                                             used. The engine Maintenance Schedule must be fol-
                                                           lowed.
      IMPORTANT!                                           Some systems, such as the components in the fuel
                                                           system, require special expertise and special testing
NOTE!                                                      equipment for service and maintenance. Some com-
are not in any way comprehensive since it is imposs-       ponents are sealed at the factory for environmental
ible to predict every circumstance under which serv-       reasons. No work should be carried out on sealed
ice work or repairs may be carried out. For this rea-      components except by authorized personnel.
son we can only highlight the risks that can arise         Bear in mind that most chemicals used on boats are
when work is carried out incorrectly in a well-equipped    harmful to the environment if used incorrectly. Volvo
workshop using working methods and tools developed         Penta recommends the use of biodegradable de-
by us.                                                     greasing agents for cleaning engine components, un-
All procedures for which there are Volvo Penta spe-        less otherwise stated in a workshop manual. Take
cial tools in this Workshop Manual are carried out         special care when working on-board, that oil and
using these. Special tools are developed to rational-      waste is taken for destruction and is not accidentally
ize working methods and make procedures as safe            pumped into the environment with bilge water.
as possible. It is therefore the responsibility of any
person using tools or working methods other than the
ones recommended by us to ensure that there is no
                                                           Tightening torques
danger of injury, damage or malfunction resulting from
these.                                                     Tightening torques for vital joints that must be
In some cases there may be special safety precau-          tightened with a torque wrench are listed in workshop
tions and instructions for the use of tools and chemi-     manual "Technical Data": "Tightening Torques" and
cals contained in this Workshop Manual. These spe-         are contained in work descriptions in this Manual. All
cial instructions should always be followed if there       torques apply for cleaned threads, screw heads and
are no separate instructions in the Workshop Manual.       mating surfaces. Torques apply for lightly oiled or dry
                                                           threads. If lubricants, locking fluid or sealing com-
Certain elementary precautions and common sense
                                                           pound are required for a screwed joint this information
can prevent most risks arising. A clean workplace
                                                           will be contained in the work description and in
and engine eliminates much of the danger of injury
                                                           "Tightening Torques" Where no tightening torque is
and malfunction.
                                                           stated for a joint use the general tightening torques
It is of the greatest importance that no dirt or foreign   according to the tables below. The tightening torques
particles get into the fuel system, lubrication system,    stated are a guide and the joint does not have to be
intake system, turbocharger, bearings and seals            tightened using a torque wrench.
when they are being worked on. The result can be
malfunction or a shorter operational life.                 Dimension                 Tightening Torques
                                                                                     Nm               lbt.ft
                                                           M5                          6                   4.4
                                                           M6                         10                   7.4
                                                           M8                         25                  18.4
                                                           M10                        50                  36.9
                                                           M12                        80                  59.0
                                                           M14                       140                 103.3




6
                                                            quired.
Tightening torques-protractor (angle)
                                                            In this Volvo Penta Service Manual the user will find
tightening
                                                            that each section where these agents are applied in
                 Tightening using both a torque setting     production states which type was used on the engine.
                 and a protractor angle requires that       During service operations use the same agent or an
                 first the recommended torque is ap-        alternative from a different manufacturer.
                 plied using a torque wrench and then
                 the recommended angle is added ac-         Make sure that mating surfaces are dry and free from
                 cording to the protractor scale. Ex-       oil, grease, paint and anti-corrosion agent before ap-
                 ample: a 90 protractor tightening         plying sealant or locking fluid. Always follow the man-
                 means that the joint is tightened a        ufacturer's instructions for use regarding; temperature
                 further 1/4 turn in one operation after    range, curing time and any other instructions for the
                 the stated tightening torque has been      product.
                 applied.                                   Two different basic types of agent are used on the
                                                            engine and these are:
                                                            RTV agent (Room temperature vulcanizing). Use for
                                                            gaskets, sealing gasket joints or coating gaskets.
Locknuts
                                                            RTV agent is clearly visible when a component has
Do not re-use lock nuts that have been removed dur-         been dismantled; old RTV must be removed before
ing dismantling as they have reduced service life           the joint is resealed. Old sealant can be removed us-
when re-used - use new nuts when assembling or re-          ing methylated spirits in all cases.
installing. For lock nuts with a plastic insert such as     Anaerobic agents. These agents cure in an absence
Nylock the tightening torque stated in the table is re-    of air. They are used when two solid parts, for ex-
duced if the Nylock  nut has the same head height as       ample cast components, are installed face-to-face
a standard hexagonal nut without plastic insert. Re-        without a gasket. They are also commonly used to
duce the tightening torque by 25% for bolt size 8 mm        secure plugs, threads in stud bolts, cocks, oil pres-
or larger. Where Nylock nuts are higher, or of the         sure switches and so on. The cured material is glass-
same height as a standard hexagonal nut, the tighten-       like and it is therefore colored to make it visible.
ing torques given in the table apply.                       Cured anaerobic agents are extremely resistant to
                                                            solvents and the old agent cannot be removed. When
                                                            reinstalling the part is carefully degreased and then
                                                            new sealant is applied.
Tolerance classes
Screws and nuts are divided into different strength
classes, the class is indicated by the number on the
bolt head. A high number indicates stronger material,
for example a bolt marked 10-9 indicates a higher tol-
erance than one marked 8-8. It is therefore important
that bolts removed during the disassembly of a bolted
joint must be reinstalled in their original position when
assembling the joint. If a bolt must be replaced check
in the replacement parts catalogue to make sure the
correct bolt is used.



Sealants
A number of sealants and locking liquids are used on
the engines. The agents have varying properties and
are used for different types of jointing strengths, oper-
ating temperature ranges, resistance to oil and other
chemicals and for the different materials and gap
sizes in the engines.
To ensure service work is correctly carried out it is
important that the correct sealant and locking fluid
type is used on the joint where the agents are re-




                                                                                                                  7
Component guide




MD11C and D
 1.   Stop device
 2.   Air bleed screw, injection pump
 3.   Injector
 4.   Delivery pipe nut
 5.   Temperature sender
 6.   Lock-screw, crankshaft centre bearing
 7.   Drain cocks, cooling water
 8.   Inspection cover
 9.   Oil drain plug, engine
10.   Oil dipstick, reverse gear
11.   Oil filler, reverse gear
12.   Oil drain plug, reverse gear
13.   Water drain plug, reverse gear
      (MD11D, connection hose)
14.   Decompression handle
      (certain models)
15.   Air filter                                   MD11C
16.   Oil filler, engine
17.   Pressure equalizing valve (certain models)
18.   Air bleed screw
19.   Fine filter
20.   Feed pump
21.   Engine speed sender
22.   Oil filter
23.   Oil pressure sender
24.   Oil strainer and oil dipstick (MD11C)
25.   Oil pump
26.   Oil dipstick, MD11D




                                                   MD11D


8
MD17C and D
 1. Fuse box                              MD17C
 2. Decompression handle, certain mo-
    dels
 3. Air filter
 4. Oil filler
 5. Air bleed screw
 6. Fine filter
 7. Feed pump
 8. Engine speed sender
 9. Oil filter
10. Stop device
11. Adjustment screw - high idle speed
12. Adjustment screw - low idle speed
13. Leak-off pipe
14. Lifting eye
15. Delivery pipe
16. Injector
17. Thermostat housing
18. Oil dipstick
19. Drain cocks, cooling water
20. Engine type and number plate
21. Cooling water pump




                                         MD17D




                                                 9
Dismantling

Drain off the engine cooling water, lubricating oil and
any fuel in the fuel filter and fuel injection pump.
Clean the outside of the engine.




                                                            2B.   The picture shows later type of injector from and
                                                                  including engine no. 50989 (MD11) and 16622
                                                                  (MD17).




1.    A fixture for securing the engine in the engine
      stand 9992520 may be used to advantage.
      MD11: 884604. MD17: 884581.
                                                            3.    Take off the coolant pipe between the sea water
                                                                  pump and the exhaust manifold. Remove the
                                                                  exhaust manifold (wrench width 13 mm).


CYLINDER HEAD




2A.   Take off the air cleaner, the leak-off oil pipe and
      the delivery pipes. Fit protective caps.              4.    Remove the valve covers. Undo the oil pipes on
      The picture shows earlier type of injector up to            the rocker arm shafts and dismantle the rocker
      and including engine no. 50988 (MD11) and                   arm bearing brackets. Take out the push rods.
      16621 (MD17).


10
                                                           CYLINDERS, CYLINDER LINERS




5.    Remove the eyebolt (or eyebolts) and nuts hold-
      ing the cylinder heads (wrench width 19 mm).
      Straighten out the oil pipes slightly and lift the
      cylinder heads off.
                                                           7.   Lift the cylinders out. Remove the cylinder liners
                                                                by placing the cylinder with the bottom of the
                                                                liner on a flat support and strike the top face of
                                                                the cylinder with a rubber mallet.


                                                           PISTONS AND CONNECTING RODS




6A.   Disconnect the cables from the engine speed
      sender, the oil pressure switch and the altern-
      ator. MD11: Remove the alternator bracket to-
      gether with the alternator. The picture shows the
      earlier model MD11C up to and including engine
      no. 52480 and MD11D from production start.
      MD17: Remove the cover (earlier models) over
      the V-belt and remove the alternator.

                                                           8.   MD11: Remove the inspection covers on the
                                                                crankcase (6 mm socket head). MD17: Remove
                                                                the oil sump and strainer. NOTE! Remove the
                                                                sealing rings in the ends of the oil pump suction
                                                                pipe.




6B.   MD11C: The picture shows the later models            9.   Remove the big-end bearing caps and take out
      from and including engine no. 52481.                      the connecting rods (and pistons). Mark the con-
                                                                necting rods (if this has not already been done).
                                                                Remove the valve tappets.

                                                                                                               11
TIMING GEAR




                                                          13A. MD11C and MD17C. Remove the carrier on the
                                                               crankshaft (engines with RB-reverse gear have
                                                               a carrier drive, use a distance piece to protect
10.   Remove the crankcase breather/hand starter.              the shaft. Take care of the key.




                                                          13B. MD11D and MD17D. Remove the carrier on the
                                                               crankshaft. Use puller 884078 (for the flywheel),
11.   Remove the injection pump, sea water pump,               use a distance piece to protect the shaft. Take
      feed pump and the fuel filter.                           care of the key. Earlier types of puller 884078
      The D-engines have leak-off oil return pipes con-        can be modified by drilling three  8.5 mm holes
      nected to the inlet union (see also page 27).            (use the spline flange as a template).




12.   Take off the timing gear cover.
                                                          14.   Pull off the crankshaft gear with the aid of tool
                                                                884078. Remove the key, the spacing washer
                                                                and the thrust washer.


12
15.   Unscrew the left handed carrier screw/nut on the
      camshaft. Pull out the cam disc and the gear-      18.   Remove the starter motor and its bracket.
      wheel together. (On MD11, the crankshaft can
      be dismantled without taking off the camshaft
      gearwheel).




16.   MD11, certain models: Remove the belt pulley       19.   Remove the oil pump.
      that is mounted on the flywheel. MD17: Remove
      the bearing shield.




FLYWHEEL




17.   Bend out the lock washer and unscrew the cent-     20.   MD11: Remove the front engine brackets. Re-
      ral nut. Pull off the flywheel using the puller          move the bearing shield.
      884078. Take care of the key. NOTE! The nut is
      pulled using 500 Nm (50 kpm = 369 lbf.ft.)


                                                                                                             13
CRANKSHAFT




                                                          23B. MD11C.                  23C. MD11D.
21.   Remove the locating screw for the crankshaft
                                                          Tool 884714.                 Hexagon, 30 mm.
      centre bearing (two in the case of MD17). Pull
      the crankshaft out.




CAMSHAFT




22.   Remove the thrust washer and lift the camshaft      24.   Loosen the lock screw and remove the centrifu-
      out. MD17: Check that the oil hole is correctly           gal governor.
      located when re-assembling.




23A. Remove the oil filter, the oil pressure switch and   25.   Unscrew the centre bearing (MD17, two bear-
     the oil pipes for the rocker arm mechanism.                ings). NOTE! Mark them so that they can be
     MD11: Remove the oil strainer. MD11C: Use tool             re-fitted in the same positions.
     884714 (see 23B). MD11D: 30 mm hexagon (see
     23C).


14
Overhauling
Cylinder head
DISMANTLING                                                VALVE GUIDES




26.   Remove the injectors and fit protective caps on      29.   Check the valve guides for wear by inserting a
      the tips of the nozzles.                                   new valve. Measure the clearance with the aid of
                                                                 a dial gauge. Replace the guides if necessary.
                                                                 Wear limits:
                                                                 Inlet valve,
                                                                 max. clearance .................. 0.15 mm (0.00591")
                                                                 Exhaust valve,
                                                                 max. clearance .................. 0.17 mm (0.00669")




27.   Remove the wear caps from the valve stems.
      Remove the valve springs with the aid of a
      valve spring compressor. Place the valves in or-
      der in a valve stand. Take off the sealing rings
      that are fitted on the valve guides.


CLEANING, INSPECTION

                                                                             A = 18 mm (0.709")

                                                           30.   Press out the valve guides using drift 9991459.
                                                                 Oil the new guides externally and press them
                                                                 into position with tool 884499. The tool should
                                                                 be pressed right down against the cylinder head.
                                                                 Ream the guides if necessary with broach
                                                                 9994128.




28.   Clean all parts. Pay particular attention to cool-
      ant passages. In case of doubt, check for leak-
      age by pressure testing. Water pressure 0.3
      MPa (3 kg/cm2 = 43 p.s.i.).

                                                                                                                  15
VALVE SEATS AND VALVES                                                        ROCKER ARM MECHANISM




A = max 2.5 mm (0.10")                       C = 45                          33.   Dismantle the rocker arm mechanism and clean
                                                                                    the parts. Check the shaft and the bushes for
B = 10.1 mm (0.0400.004")                  D = 44,5
                                                                                    wear. If the bushes need to be replaced, the tool
                                                                                    884560 is used for pressing out and in. (Ensure
31.   Mill or ream the valve seats, the angle (C)                                   that the oil hole in the bush coincides with that
      should be 45. Check the valve guides and re-                                 in the rocker arm). After having been pressed in,
      place them if necessary before machining the                                  the bushes should be reamed to give an accu-
      seats, see point 29. The width (B) of the sealing                             rate running fit. Check whether the rocker arm
      surface should be 10.1 mm (0.040"0.004").                                   surface which bears on the valve is worn. Minor
                                                                                    adjustments can be made with the valve grind-
      Grind the valves in the valve grinding machine.
                                                                                    ing machine. Oil the shaft and fit the parts.
      The angle (D) should be 44.5. If the thickness
                                                                                    NOTE! Fit the wear caps on the valve stems.
      of the edge of the disc after grinding is less than
      1.5 mm (0.059"), the valve should be rejected.
      Discard also valves with bent stems or if the di-
      mension (A) exceeds 2.5 mm (0.10"). If neces-
      sary grind the surface on which the rocker arm
      bears. Grind the valves in using grinding com-
      pound and check the surface contact using
      marking blue.


VALVE SPRINGS                                                                 VALVE TAPPETS




32.   Check the valve spring lengths both loaded and
      unloaded.
L     Length unloaded ...................................... 50 mm (1.969")   34.   Check the valve tappets for wear. The cylindri-
L1    Length when loaded with                                                       cal surface should not be scored or porous. The
      30020 N (302 kp = 66.64.41 lbf) ....... 39 mm (1.535")                     surface bearing on the camshaft should not be
L2    Length when loaded with                                                       rough or worn unevenly. Replace the tappets if
      56030 N (563 kp = 123.56.6 lbf) ......... 32 mm (1.26")                    necessary.


16
INJECTOR SLEEVE                                                    correctly). Place nuts or washers on the stud
                                                                   bolts so that the yoke can be clamped tightly
Drain the engine cooling water, if this has not already
                                                                   with the nuts. Screw the tool down as far as the
been done.
                                                                   shoulder in the sleeve permits, thus flaring the
                                                                   sleeve. Remove the tool.




35.   Remove the sleeve using the tool 884081. Push
      the expanding screw down into the sleeve and
      screw anti-clockwise so that the screw expands
      and grips the sleeve. Tighten until the threads
      bite into the copper material. Fit the yoke onto
      the stud bolts which hold the injector. Screw on
      the nut and rotate until the sleeve is removed.


                                                            38.    Adjust the length of the sleeve outside the plane
                                                                   of the cylinder head (dimension 0.9 mm,
                                                                   0.035"). Also check that the sleeve is correctly
                                                                   fitted (dimension 19.5 mm, 0.768").



                                                            INJECTORS




36.   Remove the O-ring and carefully clean the hole
      in which the sleeve is to fit. Grease and fit the
      new O-ring. Oil the new sleeve and fit it using
      tool 884077. Knock the sleeve in until it bot-
      toms.

                                                            39.    Check the spray pattern at the correct opening
                                                                   pressure. Up to and including engine no. 50988
                                                                   (MD11), 16621 (MD17):

                                                                   + 0.8          + 0.8               + 114
                                                            17.0         MPa (170       kp/cm2 = 2418  0 p.s.i.)
                                                                   0             0


                                                            From and including engine no. 50989 (MD11), 16622
                                                            (MD17):

                                                            24.5 + 0.8 MPa (245 + 0.8 kp/cm2 = 3485 + 114 p.s.i.)
                                                                 0             0                  0
37.   Oil-in the flaring tool 884085 and push it into the   Also check that the fuel jets cease simultaneously at
      sleeve (make sure that the pin is screwed back        all four holes and that there is no "dribble" afterwards.


                                                                                                                   17
                                                           Crankcase
                                                           CLEANING AND INSPECTION




Up to and including engine no. 50988 (MD11), 16621
(MD17).




From and including engine no. 50989 (MD11), 16622
(MD17).
                                                           42.   Remove all core plugs and clean the crankcase
                                                                 thoroughly. Check that all channels are free
40.   The opening pressure is adjusted by means of               from deposits and that there are no cracks in
      screwing the injector apart and replacing the ad-          the crankcase. Refit the plugs using a sealing
      justed washer (1) with a washer of suitable                compound.
      thickness.


ASSEMBLING THE CYLINDER HEAD                               REPLACEMENT OF MAIN BEARINGS




41A. Clean the cylinder head. Oil the new sealing          43.   Press the main bearings out using tool 884489
     rings for the inlet valves. Place the pin of tool           or a hydraulic press. NOTE! Check the positions
     No. 884497 in the valve guide. Push the seal                of the locking tongues so that the bearing is re-
     ring over the pin and knock the ring down care-             moved in the right direction. Clean the oil chan-
     fully using the sleeve until the pin bottoms in the         nels before fitting new bearings.
     sleeve.
B.   Oil the valve stems and smear a little grease in
     the inlet valve collet grooves. Place the valves
     in their respective guides, screw the inlet valves
     in carefully so as to avoid damaging the sealing
     rings. Fit the valve springs with the aid of a
     valve spring compressor.


18
                                                           PISTONS, LINERS




                                                           46.   Check the pistons and liners for damage and
                                                                 wear.
                  A = 1.5 mm (0.06")
                                                           A.    Measure the cylinder liners diameter at a
                                                                 number of points round the circumference and at
44A. Fit the two halves of the new bearing together              several different heights between the top and
     with an elastic cord and turn them so that the              bottom dead centre positions. (B and C). Re-
     locking tongues after pressing in fit into the ap-          place the pistons and the liners if the wear
     propriate recess. NOTE! The halves should be                amounts to 0.25 mm (0.01") or more.
     slightly staggered, see the diagram.                  B.    Measure the piston diameter (A) at right angles
                                                                 to the gudgeon pin hole and 7 mm from the bot-
                                                                 tom edge. Calculate the maximum and minimum
                                                                 piston clearance (the maximum and minimum
                                                                 liner diameter minus the piston diameter).
                                                                 Piston clearance (new): 0.09-0.13 mm
                                                                 (0.0035"-0.005").




44B. Press the bearings in with tool 884489 or using
     a hydraulic press.



CENTRIFUGAL GOVERNOR
                                                           47.   Measure the piston ring gap with the new rings.
                                                                 If the cylinder liner is not new the measurement
                                                                 should be made below the bottom dead centre
                                                                 position. For dimension, see "Technical Data''.




45.   Clean the governor. Check that the weights (2)
      do not bind on the shaft or that there is excess-
      ive clearance between the shaft and the gov-
      ernor weights. Check that the pin (1) slides free-
      ly in the shaft. Finally, inspect both the ball
      bearings (3).
      Replace the ball bearings if they bind. Check        48.   Measure the piston ring clearances in the piston
      that all moving parts are oiled and move freely            ring grooves. For dimensions, see "Technical
      before assembling in reverse order.                        Data".


                                                                                                               19
CONNECTING RODS                                            CAMSHAFT




                                                           52.   Check the camshaft for wear on the cams and
                                                                 bearing journals. Also check the wear on the
                                                                 bearings. The bearings are pressed into their re-
                                                                 cesses and must be line milled after pressing in.
49.   Check the connecting rods for straightness and             The maximum allowable wear on journals or
      twist.                                                     bearings is 0.05 mm (0.002").


                                                           OIL PUMP




                                                           53.   Remove the cover, retaining the old gasket. Re-
50.   Check the connecting rod bushings, using the               move the gearwheels, the spring and the piston.
      gudgeon pins as gauges. There should be no                 Clean all parts. Check the reducing valve spring,
      noticeable play. If it is necessary to replace the         see "Technical Data". Replace any worn or dam-
      bushings a suitable drift should be used for               aged parts.
      pressing in and out. Ensure that the oil hole in
      bushings coincides with that in the connecting
      rod.
      Ream the new bushings. The correct fit is
      achieved when an oiled gudgeon pin slides slow-
      ly through the bushing under its own weight.


CRANKSHAFT



                                                           54A. Check the axial play of the gearwheels. NOTE!
                                                                The old gasket should be included in the meas-
                                                                urement. If necessary, the number of gaskets
                                                                may be increased or reduced so as to obtain a
                                                                clearance of 0.03-0.15 mm (0.001"-0.006"). The
                                                                thickness of a new gasket is 0.10 mm (0.004").
                                                                Also inspect the cover, repair or replace as ne-
51.   Measure the big end journals and the main bear-           cessary if badly worn. Coat the gasket(s) with
      ing journals. The out-of-round should not exceed          sealant and refit the parts. Pour a little oil into
      0.06 mm (0.0024") and the taper should not ex-            the pump before mounting onto the engine.
      ceed 0.05 mm (0.002"). If these values are ex-       B.   Check the gear backlash, which should be
      ceeded, the crankshaft should be ground to a              0.15-0.35 mm (0.006-0.014"), using a feeler
      suitable undersize (see "Technical Data").                gauge. Worn gears must be replaced.

20
FEED PUMP                                                  SEA WATER PUMP
                                                           Replacing the impeller




                                                           58.   Remove the cover. Watch out for water pour-
55.   Undo the central screw in the cover, lift out the          ing through the pump. With the aid to two
      strainer and clean it. Take out the six screws             screwdrivers prise the shaft with the impeller out
      holding the upper and lower parts of the pump              of the housing sufficiently for the screw which
      together. Take out the lever spring (1), also re-          holds the impeller to be undone. NOTE! Lay
      move the screw (2).                                        some kind of protection under the screwdrivers
                                                                 so that the housing is not damaged.




56.   Remove the lever shaft using a pair of
      fine-nosed pliers. Pull out the lever and the dia-
      phragm. Fit new parts from the repair kit and re-
      assemble the pump.
                                                           59.   Take the screw out and pull the impeller off the
                                                                 shaft. Clean the housing internally and check
THERMOSTAT                                                       that the carrier (MD17) is free from defects and
                                                                 fit the new impeller. Fit the cover together with a
                                                                 new gasket.




57.   The thermostat is accessible after the thermo-
      stat housing on the front on the exhaust mani-
      fold has been taken off. Watch out for water
      pouring into the boat. Check the opening and
      closing temperatures with hot water. These           60.   MD11: Engine no. 46159-46175 and from and
      should be as given in "Technical Data". If the             including engine no. 46214. Remove the cov-
      thermostat is faulty it should be discarded. Use           er. The impeller can be pulled out as shown in
      new sealing rings when refitting (MD17 has only            the picture or by using suitable pliers. NOTE!
      one sealing ring). The picture shows the earlier           Protect the edge of the pump housing. The shaft
      type (bellows thermostat). Later engines are fit-          follows with the impeller but is stopped by a pin
      ted with a wax thermostat.                                 behind the seals.

                                                                                                                 21
61.   MD17 from and including engine no. 17973
      and MD17 - HD - HE from production start.
      The impeller is removed as shown in picture 60.
      The pump is fitted with two ball bearings (3).
      When disassembling, loosen the lock ring (2)
      and press out the shaft (the bearings following
      with the shaft). Press the bearings from the
      shaft using a suitable drift. When assembling,
      the bearings are pressed onto the shaft using
      drift 884742 until the shaft bottoms in the drift.
      The seals (1) are replaced according to point 63.
      Smear the shaft with grease and screw it care-
      fully through the sealing rings so as not to dam-
      age them. Press in the shaft until the bearing
      bottoms and fit the lock ring (2).                   63.   Remove the sealing rings (1) and the O-rings (2)
                                                                 (earlier engines) and clean the pump housing
                                                                 and shaft. Replace the impeller if necessary.
                                                                 Check that the shaft is free from burrs or
                                                                 scratches. Inspect the carrier (MD17). NOTE! A
                                                                 new O-ring (2) shall not be fitted.
                                                                 Fit new sealing rings. NOTE! Turn the sealing
                                                                 rings the right way round and ensure that they
                                                                 do not block the drainage hole in the pump
                                                                 housing. Smear the shaft with grease and fit it
                                                                 carefully into the housing, screwing it through
                                                                 the sealing rings to avoid damaging them.
Replacing the sealing rings
                                                                 Locate the shaft in the housing so that the
                                                                 screw hole lies outside: Fit the impeller and the
                                                                 screw.
                                                                 Pump having open shaft. The shaft has a
                                                                 groove which is open at the front which is why
                                                                 the impeller is assembled with the screw fitted.
                                                                 Push the impeller in until bottoms.
                                                                 Fit a new gasket into the cover and secure it
                                                                 with the screws.
                                                                 Also check the carrier screw on the camshaft.




62.   Remove the sea water pump. Watch out for wa-
      ter pouring into the boat. Take off the cover and
      press out the shaft and the impeller.




22
HAND STARTER, MD17                                         HAND STARTER, MD11




64.   Remove the cover (1) together with the drive
      and shaft. Knock out the pin (2) and press the
      shaft out. Remove the sealing ring (3).
      Remove the cover (4) and the screws (9), take
      off the gearwheel. Remove the bearing housing
      (8), knock out the pin (6) and pull out the sleeve
      (5). Take out the locking screw (7) and press out    65.   Remove the oil filler pipe (2). Undo the screws
      the shaft, the bearings, the spacer sleeve and             and take the gearwheel off. Knock out the lock-
      the sealing rings.                                         ing pin (3) and take off the sleeve (4). Take out
                                                                 the locking screw (1) and press out the shaft,
      Fit new sealing rings and replace any parts that
                                                                 the bearings, the spacer sleeve and the sealing
      are worn or damaged. Pack the bearings in with
                                                                 rings.
      grease and refit the parts.
                                                                 Fit the new sealing rings and replace any parts
                                                                 that are worn or damaged. Pack the bearings in
                                                                 with grease and refit the parts.




                                                                                                                23
Assembling
Use new gaskets, sealing rings, sealing washers and
lock washers. Grease or oil the sealing rings and oil
moving parts before fitting.


CRANKSHAFT




                                                           68.   Fit the crankshaft in the crankcase. Ensure that
                                                                 the hole for the centre bearing locating screw
                                                                 lines up with the hole in the crankcase. MD11:
                                                                 Make sure that the lug on the thrust washer fits
                                                                 into the recess in the crankcase.




66.   Fit the centre bearing (or bearings) on the crank-
      shaft. NOTE! Turn the bearing the right way
      round so that the locating screw in the crank-
      case fits into the hole (2) in the centre bearing.   69.   Replace the O-ring on the centre bearing locat-
      "1" oil passage, "2" hole for locating screw.              ing screw. Wind-on a little thread-sealing tape
                                                                 and apply Permatex to the outside. Screw the
                                                                 locating screw in so that it bottoms properly and
                                                                 then loosen it by half a turn.




                                                           70.   MD11: Replace both O-rings on the bearing
67.   MD11. Smear the two thrust washers with                    shield, see illustration. Replace the crankshaft
      grease and fit one of them on the crankshaft               sealing ring. Stick a small piece of tape over the
      turning the flat side towards the rear main bear-          keyway in the crankshaft and fit the bearing
      ing (timing gear side). The other washer is fitted         shield.
      in point 74.                                               MD17: Stick a small piece of tape over the key-
                                                                 way in the crankshaft and fit a new sealing ring.


24
                                                            74.   Place the engine so that it is resting on the fly-
                                                                  wheel. Make sure that the inner thrust washer is
                                                                  correctly located. Place the outer thrust washer
71.   Fit the starter motor and the oil pump. NOTE!
                                                                  on the crankshaft with the flat surface towards
      Put a little oil into the pump before fitting.
                                                                  the main bearing. Fit the distance washer with
      MD11: Fit the front engine brackets.                        the flat surface toward the thrust washer.



FLYWHEEL




72.   Fit the key and the flywheel (the taper must be
      perfectly clean). Tightening torque 500 Nm (50        75.   Fit the key for the crankshaft drive. Heat the
      kpm = 369 lbf.ft). Lock the nut by bending up               gearwheel to about 100C (212F) and fit it onto
      the washer.                                                 the crankshaft. Check to make sure that the in-
                                                                  ner thrust washer does not move from its cor-
                                                                  rect position.
TIMING GEAR




73.   MD17: Smear both thrust washers with grease
      and place one of them on the inner side of the
      bearing shield, turning the flat side towards the     76.   Fit the camshaft and ensure that the oil pump
      main bearing. Ensure that the lug on the washer             shaft fits into the slot in the camshaft. Lock the
      fits into the recess in the shield. Fit the bearing         screws with the lock washers. MD17: Note the
      shield onto the engine and tighten the screws.              location of the oil passage.


                                                                                                                  25
77.   Fit the camshaft drive key. Heat the gearwheel           80.   Fit the centrifugal governor. Tighten the
      to about 100C (212F) and fit it so that the                  socket-head screw on the side. NOTE! Make
      markings coincide. Fit the camshaft key.                       sure that the screw locates in the groove. Check
                                                                     that the pin (1) slides freely in the shaft. MD17:
                                                                     Fit the sea water pump carrier.




78.   Fit the cam disc and the left hand threaded
      screw/nut to the camshaft. Tightening torque: 70
      Nm (7 kpm = 50 lbf.ft.) for MD11 and 320 Nm
      (32 kpm = 231 lbf.ft.) for MD17. Check the end
      play. This should be: 0.05-0.15 mm
      (0.002"-0.006").
                                                               81A. MD11C and MD17C. Fit the timing gear cover.




79.   Fit the key for the reverse gear carrier/carrier
      drive in crankshaft keyway on the reverse gear
      side. Heat the carrier/carrier drive to about
      150C (302F) and fit it onto the crankshaft. Fit
      the large washer and the lock washer and
      tighten the screw with a torque wrench. Use a
      counterhold (in the flywheel).
      Tightening torque:
      MD11C and D ............ 70 Nm (7 kpm = 50 lbf.ft.)
      MD17C ................... 120 Nm (12 kpm = 87 lbf.ft.)
      MD17D ................... 110 Nm (11 kpm = 80 lbf.ft.)
      NOTE! At this torque the crankshaft drive is
      also completely tightened. Check the crankshaft
      axial play which should be 0.08-0.35 mm
      (0.003"-0.014"). Bend the lock washer against            81B. MD11D and MD17D. Fit the timing gear cover.
      the head of the screw. C-engines, see 81A. D-
      engines, see 81 B.
26
82.   Fit the oil pipes for the rocker arm mechanism.
      Fit the oil pressure switch and a new oil filter.
      MD11: Fit the oil strainer. NOTE! Apply Perma-
      tex to the filter's sealing surface and threads
      and tighten the cover firmly (use a torque            84.   Place the sealing rings into the cylinder grooves
      wrench), so that no air can get in and upset the            and under the liner collar. "1" yellow O-ring, "2"
      lubrication. NOTE! Don't forget the gasket.                 black O-ring and "3" black O-ring (narrow).
                                                                  Smear the rings with grease.
      Tightening torque:
      MD11C, 70 Nm (7 kpm = 50 lbf.ft.), tool 884714
      "A".
      MD11D, 120 Nm (12 kpm = 87 lbf.ft.), wrench
      width 30 mm "B".



CYLINDERS AND CYLINDER LINERS




83.   Grease and fit the sealing ring (yellow O-ring) for
      each respective cylinder liner in the groove in
      the crankcase (1). Place new shims on the             85.   Place the liner with the collar against a support
      crankcase face. If the cylinder liners are not              and put the cylinder onto the liner. Press down
      being replaced, the equivalent shim thickness,              by hand until the collar rests against the counter
      which corresponds to the figure stamped on the              bore in the cylinder. Make sure that the sealing
      crankcase surface for each respective cylinder              rings are not forced out of position during this
      (2) can be selected. The marking can be in the              operation.
      form of punch marks or figures which represent
      1/10 mm (0.004"). If new cylinder liners are fit-
      ted, fit one 0.2 mm (0.008") and one 0.3 mm
      (0.012") shim for each cylinder. Later (when
      carrying out control measurements) one of the
      shims may be removed, if necessary, after
      having been clipped. Fit the valve tappets.


                                                                                                                  27
                                                        PISTONS AND LINERS




                                                        88.   Heat the pistons to about 100C (212F). As-
                                                              semble the pistons and connecting rods as
86.   Fit the sealing rings for the push-rods and oil         shown in the illustration.
      pipe channels. The rings should be turned so
      that the narrow edges seal against the crank-
      case. Smear a little grease on the rings.




                                                        89.   Fit the piston rings using piston ring pliers. It is
                                                              immaterial which way up the upper ring and the
                                                              oil scraper ring are fitted, but the other rings are
                                                              marked "Top".
                                                              Turn the rings so that the gaps are staggered.




                                                        90.   Fit the pistons with the special tool 2823. This is
                                                              the same as that used for the B20 and B30 en-
87.   Place the cylinders on the crankcase.                   gines. Fit piston No. 1 nearest to the timing
                                                              gear. NOTE! The recess in the top of the piston
                                                              must come immediately under the nozzle.


28
                                                           94.    The value of 0.25 mm, (0.0098"), corresponding
                                                                  to t-k in the illustration is added to the dimen-
91.   Fit the big-end bearing caps so that the engine             sion "A". Dimension "B" is subtracted from the
      markings agree. NOTE! New nuts and bolts                    result of this addition. The clearance "S" ob-
      should be used when assembling.                             tained should be 0.8-0.9 mm, (0.0315-0.0354").
                                                                  If necessary, adjust the clearance with the
      Tightening torque: 65 Nm (6.5 kpm = 47 lbf.ft.).
                                                                  shims under the cylinder.
                                                                  Example:         A = 4.40 mm, (0.173")
                                                                                   B = 3.53 mm, (0.139")
                                                                                   S = A+0.25-B, (A+0.01"-B)
                                                                                   S = 4.40+0.25-3.53 = 1.12 mm
                                                                                   (0.173+0.01-0.139 = 0.044")
                                                                                   Allowable clearace = 0.8-0.9 mm,
                                                                                   (0.0315 to 0.0354").
                                                           In this case a shims of 0.3 mm (0.012") is removed
                                                           so that: "S'' becomes 1.12-0.3 = 0.82 mm
                                                           (0.044-0.012 = 0.032").


                                                           CYLINDER HEAD




92.   Press the cylinder liner down with tool 884622
      and measure the distance "A" from the liner col-
      lar to the piston in the top dead centre position.
      See also Point 94.




                                                           95.   Fit new cylinder head gaskets. Make sure that
                                                                 the stud bolts are screwed in properly.




93.   Measure the distance "B" from the downward
      projecting part of the cylinder head to the seal-
      ing plane. See also Point 94.                        96.   Put the cylinder heads on and fit new nuts but
                                                                 do not tighten them.


                                                                                                                  29
                                                        ADJUSTING THE VALVE CLEARANCE




97.   Fit the exhaust manifold but only tighten it up
      enough to align the cylinder heads. NOTE!
      Make sure that the gaskets are the right way
                                                        Valve clearance with the engine hot:
      round.
                                                              Inlet 0.30 mm, (0.0118")
                                                              Exhaust 0.35 mm, (0.0138")


                                                        100. Turn the engine over in the correct direction of
                                                             rotation until the valves for one cylinder "rock".
                                                             Then turn through a further revolution and adjust
                                                             the valves for this cylinder. Do the same for the
                                                             other cylinders. After a trial run, the valves
                                                             should be readjusted whilst the engine is still
                                                             hot.




98.   Tighten the cylinder head nuts in stages of 30,
      80 and 110 Nm (3, 8, 11 kpm = 22, 58, 80
      lbf.ft.). Tighten the exhaust manifold.




                                                        101. Fit the rocker arm covers and check the decom-
                                                              pression device as follows:
                                                        A.    Remove the oil filler plugs.
                                                        B.    Turn the engine over so that the exhaust valve
                                                              is closed.
                                                        C.    Place the handle so that it points upwards.
                                                        D.    Loosen the lock nut and screw the adjusting
99.   Check the straightness of the push rods.
                                                              screw upwards. Screw the adjusting screw down
      Roll the rods on a flat surface. Bent push rods         again so that it touches the rocker arm. Screw
      must be replaced.                                       down a further half turn and tighten the lock nut.
      Fit the push rods and the rocker arm bearing            Replace the oil filler plugs.
      brackets. Connect the oil pipes to the rocker
                                                        NOTE! The decompression device is not adjustable
      arm shafts.
                                                        on the D-engines.




30
                                                           FUEL INJECTION PUMP




102. Fit the crankcase breather and the hand starter
     where applicable.
     NOTE! After fitting the hand starter, check that
     there is backlash between its gearwheel and the
     drive on the camshaft (in the case of MD17, the
     check is made through the cover on the hand
     starter.) If there is no clearance, the number of     104A. Clean the mating surfaces on the pump and the
     gaskets under the hand starter is increased until          timing gear cover. Remove the plastic foil from
     a noticeable clearance is obtained.                        the new gasket and place the gasket on the
                                                                cover.
                                                           B.   Measure the distance from the timing gear cover
                                                                to the base circle of the pump cam (the cam
                                                                should be turned towards the crankshaft). It is
                                                                important that the distance should be 82.80.2
                                                                mm (3.26"0.008") inclusive of gasket to ensure
                                                                correct injection angle setting. If the distance is
                                                                too small increase the number of gaskets. Each
                                                                gasket is 0.20 mm (0.0079" thick).
                                                                If the distance is too great, larger rollers must
                                                                be fitted to the pump element lifters. These roll-
                                                                ers are available in sizes differing by 0.12 mm
                                                                (0.0047") in diameter. NOTE! If a pump has roll-
                                                                ers of different sizes, the diameter of each roller
                                                                should be increased by the same amount.




103. MD11: Fit the inspection covers on the crank-
     case.
     MD17: Fit the oil strainer. NOTE! Oil the sealing
     rings and place them on the ends of the pipe as
     shown in the illustration. Press the oil pipe into
     the strainer housing first and then into the crank-
     case. Fit the oil sump. Tighten the plug "1" (on
     certain engines).
                                                           105. Remove the inspection cover on the timing gear
                                                                cover and fit the injection pump. Make sure that
                                                                the pin on the control rod is correctly fitted in the
                                                                governor lever.




                                                                                                                  31
CHECKING THE CONTROL ROD TRAVEL




106. A rough adjustment of the injection quantity can
     be made as follows:
A.   Measure the distance (A) from the timing gear            109. MD11: Fit the belt pulley on the flywheel (certain
     cover to the control rod when this is completely              models).
     pressed in (towards the front of the engine).                 MD11, MD17: Fit the alternator and the V-belt.
B.   Repeat the measurement with the control rod in                Connect all electrical cables. MD17: Fit the belt
     the backward position. NOTE! The cold starting                guard (earlier models).
     device must not be engaged when taking this
     measurement. With the MD17, the cold starting
     device is disengaged by placing the tool 833839
     on the pin (C) and pushing forward.
C.   The difference between the two dimensions should
     be:
     MD11 7.10.1 mm (0.2800.004")
     MD17 6.70.1 mm (0.2640.004")
     If there is a dimension stamped on the pump
     flange, this applies. If necessary adjust by means
     of the screw (B). Replace the inspection cover.




                                                              110. Close the cooling water draincocks. Fit the air
                                                                   cleaner.



107. Fit the feed pump and the sea water pump.
     NOTE! Don't forget to fit the carrier for the sea wa-
     ter pump on MD17. Mount the coolant pipe be-
     tween the pump and the exhaust manifold.




108. Replace the fuel filter. Fit the injectors, tightening
                                                              111. Fill with lubricating oil to the correct level. See
     torque: 20 Nm (2 kpm = 14.5 lbf.ft.). Fit all fuel
                                                                   "Technical Data" for quantity and grade. NOTE! Do
     pipes and the lifting eyebolts.
                                                                   not fill so quickly so as to cause blockage of the
     To prevent the injectors seizing it is advisable to           ventilation hole (1), (later models).
     spray them with anti-rust agent prior to fitting.


32
VENTING THE FUEL SYSTEM
MD11C and MD17C




                                                         115. Unscrew the injector delivery pipe nuts, push
                                                              the stop control in and set the speed control to
112. Unscrew the venting screw on the fuel filter by          full revolutions. Press down the cold start button
     about 4 turns. Watch out for fuel spillage.              on MD11. Turn the engine over with the starter
                                                              motor until fuel comes out of the delivery pipes.
                                                              Tighten the delivery pipe nuts and start the en-
                                                              gine.
                                                              MD11D and MD17D




                                                         116A.
                                                         1.     Open the vent screw (1 above) on the fine filter.
113. Pump fuel out with the hand pump until fuel                Watch out for fuel spillage. Use pieces of rag
     comes out without air bubbles. Close the vent              (for example) at the point of ventilation.
     screw. If the pump does not work well, turn the
                                                         2.     Pump out fuel with the help of the hand pump (2
     engine over slightly so as to change the position
                                                                below) until the fuel comes out without air
     of the pump driving cam.
                                                                bubbles. Close the vent screw. If the pump does
                                                                not work well, turn the engine over slightly so as
                                                                to change the position of the pump driving cam.
                                                         Open the vent screw on the injection pump (3 above)
                                                         and pump out clean fuel without air. Close the vent
                                                         screw and open the return pipe screw (pressure equal-
                                                         izing valve) one turn (4 above). Pump out clean fuel
                                                         without air and close the return pipe screw. Loosen
                                                         each injector delivery pipe nut and turn the engine
                                                         over with the starter motor until fuel comes out.
                                                         Tighten the delivery pipe nut. Start the engine.




114. Open the vent screw on the injector pump about
     2 turns. Pump with hand pump until the fuel
     comes out without air bubbles. Close the vent
     screw while pumping.
                                                         116B. Feed pump, 2 hand pump.


                                                                                                               33
CHECKING THE INJECTION ANGLE                              ADJUSTING ENGINE SPEED




117. Unscrew the rear delivery pipe on the injection
     pump (nearest the reverse gear) and fit a Wilbr
     pipe or the level pipe 9993197.

                                                          120A. Allow the engine to warm up and then set the
                                                               low idling speed adjusting screw (2) so that di-
                                                               mension A in the diagram is 14 mm (0.551").
                                                               B. Start the engine and loosen the lock screw
                                                               (1) on the lever.
                                                               C. Turn the lever against the stop (2). Then, us-
                                                               ing a screwdriver, turn the governor shaft so as
                                                               to obtain a speed of 12.5-13.5 r/s (750-810 r/
                                                               min). Tighten the levers' lock screw in this posi-
                                                               tion.
118. MD11: Set the speed control to max. NOTE!                 D. Turn the lever up to the adjusting screw (3)
     The cold start device must not be engaged.                and check the high idling speed, which should
     MD17: Remove the inspection cover on the tim-             be MD11C, 17C: 44 r/s (2640 r/min) MD11D,
     ing gear cover. Push the cold start pin forward           17D: 46 r/s (2760 r/min) for pleasure use and 42
     using the tool 833839 at the same time as the             r/s (2520 r/min) for HD variant. Adjust the speed
     speed control is set to max.                              if necessary.




119. Turn the engine over in the direction of rotation
     until the level pipe is filled with air-free fuel.
     Open the level screw on the Wilbr pipe so that
     the level lies at 25-30 mm (1-1.2") measured up-
     wards. Turn the engine over slowly until the fuel
     just begins to rise in the pipe. The angle mark-
     ings on the flywheel should now be at 24-26
     B.T.D.C. Adjust the injection angle if necessary
     by increasing or reducing the number of gaskets
     under the injection pump.
     MD11, use tool 884595. MD17, mark on the belt
     guard or use tool 884741.


34
Electrical system
IMPORTANT                                                     3.   When starting with the aid of an auxiliary bat-
                                                                   tery, first check to make sure that the auxiliary
The following applies to engines fitted with alternators.
                                                                   battery has the same rated voltage as the
1.       Never interrupt the circuit between the alternator        standard battery. Connect the auxiliary battery
         and the battery while the engine is running.              to the standard battery with positive to positive
         Otherwise the charging regulator will be ruined.          and negative to negative. Remove the auxiliary
         If a main switch is fitted, it must not be                battery when the engine has started. NOTE! On
         switched off until the engine has stopped. Other-         no account must the cables to the standard bat-
         wise no cable must be disconnected while the              tery be disconnected in this operation.
         engine is running, since this can also ruin the      4.   When carrying out electrical welding on the en-
         charging regulator.                                       gine or installation components, the charging
2.       Check regularly the battery, battery cables and           regulator cables must first be disconnected and
         cable terminals. The battery poles should be              insulated. Both the battery cables must also be
         well cleaned and the terminals tightened and              disconnected.
         well-greased to ensure continuous function. All      5.   Before carrying out any repairs on the alternator
         cables in general must be well-tightened and dry          equipment, always first disconnect both the bat-
         and sprayed with moisture inhibiting spray.               tery cables. The same applies if the battery has
         NOTE! On no account must the battery's posi-              to be rapidly charged.
         tive and negative poles be mixed up when the         6.   Never test any of the components with a screw-
         battery is fitted.                                        driver or similar tool against a connection to see
                                                                   if there is any spark.

                                              WIRING DIAGRAM
POSITION LIST
 1.    Temperature gauge
 2.    Revolution counter
 3.    Charging warning lamp
 4.    Oil pressure warning lamp
 5.    Key switch
 6.    Switch, instrument lighting
 7.    Switch, extra equipment
 8.    Connector
 9.    Starter motor
10.    Alternator
11.    Fuse box
12.    Main switch
13.    Engine speed sender
14.    Oil pressure sender
15.    Temperature sender
16.    Battery


WIRING CODE
Symb. Colour              mm 2       AWG
A           White         6          9
B           Black         1.5        15
B'          Black         0.6        19
C           Red           6          9
C'          Red           35         1
C''         Red           0.6        19
C'''        Red           2.5        13
D           Grey          1.5        15
F           Yellow        1.5        15
G           Brown         1.5        15
H           Blue          4          11
H'          Blue          35         1
H''         Blue          1.5        15
J           Green         1.5        15
J'          Green         0.6        19



                                                                                                                   35
Fault finding table

 Engine      Engine   Engine does not   Engine runs   Engine       CAUSE OF TROUBLE
 does        stops    reach correct     irregularly   becomes
 not start            working           or vibrates   abnormally
                      speed on full     abnormally    hot
                      throttle
 X                                                                 Stop control not pressed in.
                                                                   Main switch not closed. Battery
                                                                   discharged. Break in cable or
                                                                   main fuse block.

 X            X                                                    Fuel tank empty. Fuel cock
                                                                   closed. Fuel filter blocked.

 X            X                         X                          Water or impurities in fuel.
                                                                   Faulty injectors. Air in fuel sys-
                                                                   tem.

                      X                                            Faulty rev. counter. Boat loaded
                                                                   abnormally. Air cleaner
                                                                   blocked. Fouling on boat bot-
                                                                   tom.
                      X                 X                          Incorrect engine aligning. Pro-
                                                                   peller damaged.

                                                      X            Obstruction in cooling water in-
                                                                   take or cooling jackets.
                                                                   Sea-water pump impeller fault.
                                                                   Thermostat faulty.




36
Special tools

 833839         Tool for disengaging the cold starting device
                when setting the control rod travel, MD17.




 884077         Drift for assembling injector sleeve.




 884078         Puller for flywheel, carrier (D-engines) and crank-
                shaft




 884081         Injector sleeve extractor




 884085         Flaring tool, injector sleeve.




 884489         Tool for removing and fitting of main bearings.




 884497         Drift for assembling valve sealing rings.




 884499         Drift for assembling valve guides.




 884560         Drift for removing and fitting rocker arm bear-
                ings.



 884742         Drift for assembling bearings onto sea water
                pump shaft, MD17.




                                                                  37
      884714     Key for oil strainer MD11C.




     884581      Fixture for attaching engine to stand, MD17.
                 Use together with engine stand 9992520 and at-
                 tachment flange 884583.




     884604      Fixture for attaching engine to stand, MD11.
                 Use together with engine stand 9992520, at-
                 tachment flange 884583 and attachment screw
                 884623.




     884579      Tool for dismantling oil filter.




884595 (MD11)    Tool for checking injection pump setting.
 884741 (MD17)




     884622      Pressing tool for fitting of cylinder liners.




     9991459     Drift for removing valve guides.



     9992823     Piston assembly ring (standard dimension).




     9993197     Level tube for injection pump setting.



     9994128     Valve guide reamer.




38
Technical Data
GENERAL
Type designation .............................................................            MD11C         MD11D         MD17C          MD17D
Output1) at 41.7 r/s (2500 r/min) ......................................                  17 kW (23 hp)               26 kW (35 hp)
at 50 r/s (3000 r/min) .......................................................                          18.4 kW                      26.5 kW
       ...............................................................................                  (25 hp)                      (36 hp)
Output2) at 38.3 r/s (2300 r/min) HD-engine ....................                          15 kW         15 kW         22 kW          22 kW
       ...............................................................................    (20 hp)       (20 hp)       (30 hp)        (30 hp)
MD11D/MSB Output2) at 41,7 r/s (2500 r/min) ...............                                                17 kW (23 hp)
Number of cylinders ........................................................              2             2             3              3
Bore mm (in) ....................................................................                         88.9 mm (3.5")
Stroke mm (in) .................................................................                           90 mm (3.54")
Displacement, dm3 (cu.in) ...............................................                 1.12 dm3                    1.68 dm3
       ...............................................................................    (68.35 cu.in)               (102.51 cu.in)
Compression ratio ...........................................................                                  17.5:1
Compression pressure at starter motor speed
3.3-4.2 r/s (200-250 r/min) ...............................................                     2-2.5 MPa (20-25 kp/cm2 = 284-355 p.s.i.)
Direction of rotation viewed from flywheel ......................                                            Clockwise
High speed idling (overspeed) .........................................                   2700-         3300-         2700-        3300-
       ...............................................................................    2800 r/min    3350 r/min    2800 r/min    3350 r/min
Heavy duty engine ...........................................................             2500-         2800-         2500-        2800-
       ...............................................................................    2600 r/min    2900 r/min    2600 r/min    2900 r/min
Low speed idling ..............................................................                            750-810 r/min

CYLINDER LINERS
Material ............................................................................                        Cast iron
                                                                                                                  +0.005
Diameter ..........................................................................                     88.90 mm         mm
                                                                                                                  0.010

                                                                                                               3.54 +0.0002")
                                                                                                                    0.0004")
PISTONS
Material ............................................................................                       Aluminium
Diameter, cylinder bore ...................................................                             88.78-88.80 mm (3.4953"-3.4961")
Height total mm (in) .........................................................                            98 mm (3.858")
Height from centre of gudgeon pin to top of piston mm (in)                                                65 mm (2.559")
Piston clearance in cylinder liner mm (in) ......................                                       0.09-0.13 mm (0.00354-0.00512")

GUDGEON PINS
Diameter mm (in) .............................................................                          28.00-28.004 mm (1.10236-1.10252")
Gudgeon pin bearing diameter mm (in) ...........................                                        28.014-28.025 mm (1.10291-1.10334")
Clearance gudgeon pin - bearing ....................................                                     Close running fit

PISTON RINGS
Compression rings, number ............................................                                          3
Oil rings, number .............................................................                                 1
The upper compression ring is chrome plated.
Piston ring axial clearance in groove:
1st compression ring .......................................................                            0.08-0.11 mm (0.00315-0.00433")
2nd ...............................................................................                     0.06-0.092 mm (0.00236-0.00362")
3rd     ...............................................................................                 0.03-0.062 mm (0.00118-0.00244")
Oil ring ..............................................................................                 0.03-0.062 mm (0.00118-0.00244")
Piston ring gap measured in cylinder liner:
1st compression ring .......................................................                            0.40-0.55 mm (0.0157-0.0217")
2nd and 3rd ......................................................................                      0.30-0.45 mm (0.0118-0.0177")
Oil ring ..............................................................................                 0.25-0.40 mm (0.0100-0.0157")

1)
     Propeller shaft output, DIN 6270 Leistung B fr Dauerbetrieb.
2)
     Propeller shaft output for "run-in" engines with reverse gear. DIN 6270 Leistung B fr Dauerbetrieb.
                                                                                                                                               39
                                                                                        MD11C         MD11D          MD17C           MD17D
CYLINDER HEAD
Material ............................................................................               Specially alloy cast-iron

CRANKSHAFT AND BEARINGS
Crankshaft axial clearance mm (in) ................................                          0.08-0.35 mm (0.00315-0.01378")
Main bearings radial clearance mm (in) ..........................                           0.038-0.100 mm (0.00150-0.00394")
Big-end bearings radial clearance mm (in) .....................                             0.054-0.099 mm (0.00213-0.00390")

MAIN BEARING JOURNALS
Diameter
standard ...........................................................................       66.646-66.665 mm (2.62386-2.62461")
0.254 mm undersize (0.010") ..........................................                     66.392-66.411 mm (2.61386-2.61461")
0.508 mm undersize (0.020") ..........................................                     66.138-66.157 mm (2.60386-2.60461 ")
0.762 mm undersize (0.030") ..........................................                      65.884-65.903 mm (2.5939-2.5946")

MAIN BEARING SHELLS
Thickness
standard mm (in) .............................................................             2.136-2.145 mm (0.08409-0.08445")
0.254 mm oversize (0.010") ............................................                    2.263-2.272 mm (0.08909-0.08945")
0.508 mm oversize (0.020") ............................................                    2.390-2.399 mm (0.09409-0.094449")
0.762 mm oversize (0.030") ............................................                    2.517-2.526 mm (0.09909-0.09945")

BIG-END BEARING JOURNALS
Diameter
standard mm (in) .............................................................             53.966-53.985    mm   (2.12465-2.12539")
0.254 mm undersize (0.010") ..........................................                     53.712-53.731    mm   (2.11465-2.11539")
0.508 mm undersize (0.020") ..........................................                     53.458-53.477    mm   (2.10465-2.10539")
0.762 mm undersize (0.030") ..........................................                     53.204-53.223    mm   (2.09465-2.09539")

BIG-END BEARING SHELLS
Thickness
standard mm (in) .............................................................              1.384-1.391   mm   (0.05449-0.05476")
0.254 mm oversize (0.010") ............................................                     1.511-1.518   mm   (0.05949-0.05976")
0.508 mm oversize (0.020") ............................................                     1.638-1.645   mm   (0.06449-0.06476")
0.762 mm oversize (0.030") ............................................                     1.765-1.772   mm   (0.06949-0.06976")

CONNECTING ROD
Axial clearance at crankshaft mm (in) ............................                              0.05-0.25 mm (0.00197-0.00984")

CAMSHAFT
Axial clearance ................................................................                0.05-0.15 mm (0.00197-0.00591")
Radial clearance in bearing .............................................                       0.03-0.09 mm (0.00118-0.00354")
Bearing journals, diameter
No. 1 ...............................................................................       31.700-31.725    mm   (1.2480-1.2490")
No. 2 ...............................................................................       46.975-47.000    mm   (1.8494-1.8504")
No. 3 ...............................................................................       48.975-49.000    mm   (1.9281-1.9291")
No. 4, (MD17) ..................................................................            54.970-55.000    mm   (2.1642-2.1654")
The bearings are reamed after pressing in
Cam lift mm (in) ...............................................................                5.75-5.85 mm (0.22638-0.23032")

VALVE SYSTEM
Inlet
Valve disc diameter .........................................................                        38 mm (1.49606")
Stem diameter mm (in) ...................................................                   7.955-7.970 mm (0.31319-0.31378")
Valve seat angle ..............................................................                            44.5
Cylinder head seat angle .................................................                                 45.0
Seat width in cylinder head mm (in) ...............................                                ca 1.0 mm (0.03937")
Clearance, engine warm mm (in) ....................................                                 0.30 mm (0.0118")


40
Exhaust                                                                                  MD11C          MD11D        MD17C        MD17D
Valve disc diameter mm (in) ...........................................                                  34 mm (1.33858")
Stem diameter mm (in) ...................................................                               7.950-7.965 mm (0.31299-0.31358")
Valve seat angle ..............................................................                                44.5
Cylinder head seat angle .................................................                                     45.0
Seat width in cylinder head mm (in) ...............................                                     ca 1.0 mm (0.03937")
Clearance, engine warm mm (in) ....................................                                     0.35 mm (0.0138")
DECOMPRESSION DEVICE
Max. downward pressing of exhaust valve
(not adjustable on D-engines) mm (in) ............................                                        0.5 mm (0.01969"
VALVE GUIDES
Length, inlet mm (in) .......................................................                            59 mm (2.32283")
exhaust mm (in) ...............................................................                          52 mm (2.04724")
Bore diameter after assembly and reaming mm (in) ......                                                 8.0 mm-8.015 mm (0.31496-0.31555")
Height above cylinder head spring surface ....................                                           18 mm (0.70866")
Clearance valve stem-guide
      inlet .........................................................................                    0.03-0.06 mm (0.00118-0.00236")
      exhaust ..................................................................                         0.03-0.07 mm (0.00118-0.00276")
VALVE SPRINGS
Free length, unloaded ......................................................                             50 mm (1.96850")
loaded with 30020 N (302 kp) (66.1394.41 lbf). .......                                                39 mm (1.535432")
      56030 N (563 kp) (123.56.6 lbf) ......................                                          32 mm (1.25984")
LUBRICATING SYSTEM
Oil capacity, engine inclination 0
(For inclined engines fill oil to the upper mark on dipstick)
  Engine excl. filter .........................................................          2.6 dm3                          4.4 dm3
                                                                                         (0.7 US galls 0.6 UK galls)    (1.16 US galls 0.96 UK galls)
               incl. filter .........................................................    2.85 dm3                         4.65 dm3
                                                                                         (0.75 US galls 0.63 UK galls) (1.23 US galls 1.02 UK galls)
Engine incl. RB reverse gear, excl. filter ........................                      3.0 dm3                          4.8 dm3
                                                                                         (0.79 US galls 0.66 UK galls) (1,27 US galls 1.05 UK galls)
            incl. filter .............................................................   3.25 dm3                         5.05 dm3
                                                                                         (0.86 US galls 0.71 UK galls) (1.33 US galls 1.1 UK galls)
Oil quality ace. to API-system, diesel lubricating oil,
service .............................................................................                          CD (DS)
Viscosity
over +10C (50F) Volvo Penta CD oil Double grade .....                                                     SAE 20W/30
under +10C (50F) Volvo Penta CD oil Single grade ....                                                       SAE 10W
Oil pressure, warm engine idle speed .............................                                       0.1-0.2 MPa (1-2 kp/cm2) (14-28 p.s.i.)
full speed .........................................................................                     0.2-0.3 MPa (2-3 kp/cm2) (28-43 p.s.i)

LUBRICATION OIL PUMP
Type ...............................................................................                             Gear
Spring for reducing valve:
Free length, unloaded ......................................................                                40 mm (1.58")
  loaded with 252 N (2.50.2 kp) (5.50.44 lbf) ..........                                                 34 mm (1.34")
                 352 N (3.50.2 kp) (7.70.44 lbf) ..........                                             31.5 mm (1.24")
Axial gear clearance incl. gasket ....................................                                   0.03-0.15 mm (0.00118-0.00591")

FUEL SYSTEM
Injection pump manufacturer, Bosch
Injector manufacturer, Bosch hole diameter ..................                                          4 st 0.27 mm (0.01063")
opening pressure ..................................................... MPa               17.0 +0,8     24.6 +0.8    17.0 +0.8            24.5 +0.8
                                                                                              0            0           0                   0
                                                                         (kp/cm2)        (170 +8  )    (245 +8  )   (170 +8 )                +8
                                                                                                                                         (245 )
                                                                                              0            0           0                  0
                                                                                               +114          +114         +114                 +114
                                                                            (p.s.i.)     (2418      ) (3485       ) (24180 )           (3485       )
                                                                                               0            0                                0
Injection angle B.T.D.C ...................................................              24-26        24.5-26.5   24-26               24.5-26.5
Injection quantity .............................................................         35-36 mm3/stroke at 20C (68F) and 16.5       r/s
                                                                                         (1000 r/min) pump speed
HD-variant ........................................................................      33-34 mm3/stroke at 20C (68F) and 16.5       r/s
                                                                                         (1000 r/min) pump speed
                                                                                                                                                  41
FINE FILTER                                                                              MD11C and D                      MD17C and D
Type .................................................................................                    Spin-on
Earlier type ......................................................................                     Filter insert

FEED PUMP
Feed pressure at 42 r/s (2520 r/min) ..............................                      65-85 kPa (0.65-0.85 kp/cm2) (9.25-12.1 p.s.i.)

ELECTRICAL SYSTEM
Battery voltage ................................................................                            12 V
Battery capacity, pleasure use (starter motor battery) ..                                max 70 Ah                        max 90 Ah
HD variant (starter motor battery) ...................................                   max 90 Ah                        max 90 Ah
Starter motor output
  pleasure use ................................................................          1.1 kW (1.47 hp)                 1.9 kW (2.55 hp)
  HD variant ....................................................................        1.9 kW (2.55 hp)                 1.9 kW (2.55 hp)
Alternator
Output MD11C, MD17C ..................................................                   35 A (490 W)
        MD11D, MD17D, ................................................                   50 A (700 W)
Battery electrolyte, specific gravity:
  Fully charged battery ...................................................              1.275-1.285 g/cm3 (0.0460-0.0464 lb/in3)
  Battery to be recharged at ...........................................                       1.230 g/cm3 (0.0444 lb/in3)

COOLING SYSTEM
Thermostat, type .............................................................             Bellows (Replaceable with wax type)
            WAX from and including engine no ............                                49685                          15740
  Begins to open at .........................................................                         60C (140F)
  Fully open at ................................................................                      74C (165F)
HDHE engine
  Begins to open at .........................................................                           74C (165F)
  Fully open at ................................................................                        89C (192F)

WEAR TOLERANCES
Cylinder liners and pistons should be replaced when
0.25 mm (0.010") wear can be measured.

Crankshaft
Permissible out-of-round on main and big-end
bearing journals, max ......................................................                         0.06 mm (0.00236")
Permissible taper on main and big-end
bearing journals, max ......................................................                         0.05 mm (0.00197")
Max crankshaft end play .................................................                            0.45 mm (0.01772")

Valves
Valve stem, max permissible wear .................................                                   0.02 mm (0.00079")
Max. clearance between valve stem and valve guides:
Inlet valves ......................................................................                  0.15 mm (0.00591")
Exhaust valves ................................................................                      0.17 mm (0.00669")
The valve disc edge shall be at least .............................                                    1.5 mm (0.059")
Distance from valve disc (new valve) to the cylinder
head face, max ................................................................                      2.5 mm (0.09843")

Camshaft
Maximum permissible wear in bearing journals
and bearings ....................................................................                    0.05 mm (0.0020")




42
TIGHTENING TORQUES                                                                          MD11C and D                    MD17C and D
Cylinder head nuts* .........................................................                    110 Nm (11 kpm) (80 lbf.ft.)
Centre bearing .................................................................                 70 Nm (7.0 kpm) (50 lbf.ft.)
Big-end bearings ..............................................................                  65 Nm (6.5 kpm) (47 lbf.ft.)
Shield for main bearings .................................................                       40 Nm (4.0 kpm) (29 lbf.ft.)
Screw for carrier and carrier drive on crankshaft
(for reverse gear) .............................................................            70 Nm (7.0 kpm)          120 Nm (12.0 kpm) C-eng.
                                                                                            (50 lbf.ft.)                      (87 lbf.ft.)
.........................................................................................                           110 Nm (11.0 kpm) D-eng.
                                                                                                                              (80 lbf.ft.)
Flywheel nut ....................................................................                  500 Nm (50 kpm) (369 lbf.ft.)
Injectors ...........................................................................              20 Nm (2.0 kpm) (14.5 lbf.ft.)
Carrier for water pump .....................................................                70 Nm (7.0 kpm)                   320 Nm (32.0 kpm)
                                                                                            (50 lbf.ft.)                      (231 lbf.ft.)
Cap nuts for valve cover .................................................                          15 Nm (1.5 kpm) (11 lbf.ft.)
Nipple for oil filter .............................................................                 40 Nm (4.0 kpm) (29 lbf.ft.)
Cover for oil strainer MD11 C ..........................................                    70 Nm (7.0 kpm)
                                                                                            (50 lbf.ft.)
                                MD11 D ..........................................           120 Nm (12.0 kpm)
                                                                                            (87 lbf.ft.)
* NOTE! Tightening shall be carried out in 3 stages.
1st stage: 30 Nm (3 kpm) (22 lbf.ft.)
2nd stage: 80 Nm (8 kpm) (58 lbf.ft.)
Final stage: 110 Nm (11 kpm) (80 lbf.ft.)

COOLING SYSTEM,
DIAGRAMMATIC SKETCH




                                                                                                                1.   Reverse gear
                                                                                                                2.   Sea water pump
                                                                                                                3.   Thermostat
                                                                                                                4.   Thermostat housing




                                                                                                                                            43
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44
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                                                                           AB Volvo Penta
                                                                          Customer Support
                                                                            Dept. 42200
                                                                        SE-405 08 Gothenburg
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7739341-1 English 09-1998


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