Volvo MD2010 Workshop Manual Download Page 4

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Always use protective glasses or goggles when

carrying out work where there is a risk of splin-

ters, grinding sparks, acid splashes or where

other chemicals are used. The eyes are ex-

tremely sensitive, an injury could result in blind-

ness!

Avoid getting oil on the skin! Repeated expo-

sure to oil or exposure over a long period can

result in the skin becoming dry. Irritation, dry-

ness and eczema and other skin problems can

then occur. Used oil is more dangerous than

fresh oil from a health aspect. Use protective

gloves and avoid oil soaked clothes and shop

rags. Wash regularly, especially before eating.

There are special skin creams which counteract

drying out of the skin and make it easier to clean

off dirt after work is completed.

Many chemicals used on the product (for ex-

ample engine and transmission oils, glycol,

gasoline and diesel oil), or chemicals used in

the workshop (for example degreasing agents,

paint and solvents) are dangerous to health.

Read the instructions on the product packaging

carefully! Always follow the safety precautions

for the product (for example use of protective

mask, glasses, gloves

.). Make sure that other

personnel are not exposed to hazardous chemi-

cals, for example in the air. Ensure good ventila-

tion in the work place. Follow the instructions

provided when disposing of used or leftover

chemicals.

extreme care when leak detecting on

the fuel system and testing the fuel injector jets.

Use eye protection. The jet from a fuel injector

nozzle is under extremely high pressure and

has great penetrative energy, so the fuel can

penetrate deep into the body tissue and cause

serious personal injury. Danger of blood poison-

i ng.

All fuels and many chemical substances are

flammable. Do not allow naked flame or sparks

in the vicinity. Fuel, certain thinner products and

hydrogen from batteries can be extremely flam-

mable and explosive when mixed with air.

Smoking is not to be permitted in the vicinity!

Ensure that the work area is well ventilated and

take the necessary safety precautions before

starting welding or grinding work. Always en-

sure that there are fire extinguishers at hand

when work is being carried out.

Ensure that rags soaked in oil or fuel and used

fuel or oil filters are stored safely. Rags soaked

in oil can spontaneously ignite under certain cir-

cumstances. Used fuel and oil filters are envi-

ronmentally dangerous waste and must be de-

posited at an approved site for destruction

together with used lubricating oil, contaminated

fuel, paint remnants, solvent, degreasing agents

and waste from washing parts.

Never expose a battery to naked flame or elec-

trical sparks. Never smoke in proximity to the

batteries. The batteries give off hydrogen gas

during charging which when mixed with air can

form an explosive gas -

. This gas

is easily ignited and highly volatile. Incorrect

connection of the battery can cause a single

spark which is sufficient to cause an explosion

with resulting damage. Do not shift the connec-

tions when attempting to start the engine (spark

risk) and do not lean over any of the batteries.

Always ensure that the Plus (positive) and Mi-

nus (negative) battery leads are correctly in-

stalled on the corresponding terminal posts on

the batteries. Incorrect installation can result in

serious damage to the electrical equipment. Re-

fer to the wiring diagrams.

Always use protective goggles when charging

and handling the batteries. Battery electrolyte

contains sulfuric acid which is highly corrosive.

Should the battery electrolyte come into contact

with unprotected skin wash off immediately us-

ing plenty of water and soap. If battery acid

comes in contact with the eyes, immediately

flush with plenty of water and obtain medical as-

sistance at once.

Turn the engine off and turn off the power at the

main

) before carrying out work on the

electrical system.

Clutch adjustments must be carried out with the

engine stopped.

Summary of Contents for MD2010

Page 1: ...Workshop Manual Engine MD2010 MD2020 MD2030 MD2040 A 2 0 ...

Page 2: ...oling system Description 62 Description 24 Repair instructions Repair instructions Refrigerants 63 Cylinder head 25 Checking of refrigerant level 64 Valves valve mechanism 28 Cleaning 65 Cylinder block pistons connecting rods 34 Circulation pump 66 Timing gears 40 Sea water pump 66 Camshaft 44 Replacing the thermostat 67 Crank mechanism 46 Checking the thermostat 67 Lubricating system Description ...

Page 3: ...less movements or a dropped tool can result in personal injury Take care to avoid contact with hot surfaces ex haust pipes Turbocharger TC air intake pipe start element etc and hot liquids in lines and hoses on an engine which is running or which has just been stopped Reinstall all protective parts removed during service operations before starting the engine Safety Precautions 0 0 Check that the w...

Page 4: ...le and explosive when mixed with air Smoking is not to be permitted in the vicinity Ensure that the work area is well ventilated and take the necessary safety precautions before starting welding or grinding work Always en sure that there are fire extinguishers at hand when work is being carried out O 2L 0 Ensure that rags soaked in oil or fuel and used fuel or oil filters are stored safely Rags so...

Page 5: ...ample the United States Coast Guard Safety Regula tions Volvo Penta Original Spare Parts meet these specifications Any type of damage which is the result of using replacement parts that are not original Volvo Pen ta replacement parts for the product in question will not be covered under any warranty or guarantee provided by AB Volvo Penta Certified engines For engines certified for national and re...

Page 6: ... entering the parts or systems since this can result in reduced service life or malfunc tions 6 WARNING IMPORTANT Repair instructions and methods Our joint responsibility Every engine consists of many systems and compon ents that work together If one component deviates from the technical specifications this can have dramatic con sequences on the environmental impact of the engine even if it is oth...

Page 7: ...rent materials and gap sizes in the engines To ensure service work is correctly carried out it is im portant that the correct sealant and locking fluid type is used on the joint where the agents are required In this Volvo Penta Workshop Manual the user will find that each section where these agents are applied in production states which type was used on the engine During service operations use the...

Page 8: ...et ylene torch or be burned up afterwards in an uncontrolled manner Always use gloves made of chloroprene rubber gloves for handling chemicals and protective goggles Handle the removed seal in the same way as corrosive acid All residue including ash can be highly corrosive Never use compressed air to blow anything clean Put the remains in a plastic box which is sealed and provided with a warning l...

Page 9: ...nt Clockwise Clockwise Clockwise Clockwise Max permissible angle backwards during operation 20 200 200 20 Max side angle during operation 30 30 30 30 Valve clearance idle cold engine inlet and outlet 0 20 mm 0 20 mm 0 20 mm 0 20 mm 0078 in 0078 in 0078 in 0078 in Weight engine without oil and water 98 kg 116 kg 129 kg 179 kg 215 9lb 255 5lb 284 2lb 394 3 Ib Max permissible counter pressure in exha...

Page 10: ...9 7481 in M D2010 M D2020 54 9 55 1 2 161 2 169 in 25 35 25 45 9980 1 001 in 21 85 21 95 8602 8641 in 2 05 2 15 0807 0846 in M D2020 0 1 0 3 0039 0118 in 0 035 0 072 0013 0028 in 0 035 0 072 0013 0028 in 0 055 0 092 0021 0036 in M D2030 M D2040 0 15 0 27 0 20 0 35 0059 0106 in 0078 0137 in 0 12 0 24 0 20 0 40 0047 0094 in 0078 0157 in 0 20 0 35 0 20 0 40 0078 0137 in 0078 0157 in 0 06 0 10 0 065 0...

Page 11: ...n 1 6915 1 6919 in No 2 45 964 45 975 42 964 42 975 1 8096 1 8100 in 1 8096 1 8100 in No 3 45 964 45 975 1 8096 1 8100 in undersize No 1 0 25 mm 42 760 42 786 42 760 42 786 0098 in 1 6834 1 6844 in 1 6834 1 6844 in 0 50 mm 42 510 42 536 42 510 42 536 0196 in 1 6736 1 6746 i n 1 6736 1 6746 in undersize No 2 0 25 mm 45 764 45 790 42 760 42 786 0098 in 1 8017 1 8027 i n 1 6834 1 6844 in 0 50 mm 45 5...

Page 12: ...ine 0 20 0 20 0 20 0078 in 0078 in 0078 in MD2010 MD2020 M D2030 M D2040 Fitted with replaceable bearing shells Diameter gudgeon bushing s bearing position 21 000 21 021 23 000 23 021 30 500 30 516 8267 8275 in 9055 9063 in 1 2007 1 2014 in Bearing shell s bearing position 19 015 19 026 21 010 21 021 28 010 28 021 7486 7490 in 0827 8275 in 1 1027 1 1031 in Gudgeon bushing 19 015 19 026 21 010 21 0...

Page 13: ...mm 0 01 0 15 mm 0 01 0 15 mm 0004 0059 in 0004 0059 in 0004 0059 in 0004 0059 in Oil quality as per API system Viscosity at 5 to 50 C 23 to 122 F CD SAE 15W 40 CD SAE 15W 40 CD SAE 15W 40 CD SAE 15W 40 SAE 20W 50 SAE 20W 50 SAE 20W 50 SAE 20W 50 Max Oil volume incl oil filter no engine tilt version A B no engine tilt version C Min Oil volume incl oil filter no engine tilt version A B 1 8 litres 1 ...

Page 14: ...p cm 2 115 125 kp cm2 115 125 kp cm2 155 165 kp cm 2 1639 1784 lbf in 2 1639 1784 lbf in2 1639 1784 lbf in 2 2205 2347 lbf in 2 Opening pressure adjustment 11 8 MPa 11 8 MPa 11 8 MPa 15 7 MPa 120 kp cm2 120 kp cm2 120 kp cm2 160 kp cm2 Needle valve diameter 1711 lbf int 3 5 mm 1711 lbf int 3 5 mm 1711 lbf int 6mm 2276 lbf int 4mm 0 1378 in 0 1378 in 0 2362 in 0 1575 in Journal diameter 1 mm 0 0394...

Page 15: ...tortion top plane Cylinder diameter MD2010 MD2020 0 2 mm 00787 in oversize 0 5 mm 01969 in oversize MD2030 0 5 mm 01969 in oversize 1 0 mm 03937 in oversize MD2040 0 5 mm 01969 in oversize 1 0 mm 03937 in oversize max 0 25 mm 0098 in max 0 25 mm 0098 in max 0 15 mm 0059 in max 1 0 mm 0393 in min 18 98 mm 7472 in min 20 98 mm 8259 in min 27 98 mm 1 1015 in max 0 08 mm 0031 in max 0 02 mm 0007 in ma...

Page 16: ...nkshaft connecting rod max 0 7 mm 02755 in Valves Max valve clearance inlet and outlet cold engine max 0 5 mm 01968 in Maximum permitted valve clearance before adjustment must be carried out Starter motor Commutator diameter MD2010 MD2020 MD2040 min 31 mm 1 2204 in MD2030 min 40 mm 1 5748 in Brush length min 11 5 mm 4527 in Brush spring tension MD2010 MD2020 MD2040 min 8 8 N 2 0 lbf Brush spring t...

Page 17: ... pump 9 13 6 6 9 6 9 13 6 6 9 6 9 13 6 6 9 6 Bottom plate 9 12 6 6 8 6 9 12 6 6 8 6 9 12 6 6 8 6 Sump 9 13 6 6 9 6 9 13 6 6 9 6 9 13 6 6 9 6 Drain plug sump 30 40 22 1 29 5 30 40 22 1 29 5 30 40 22 1 29 5 Timing gear casing 9 12 6 6 8 6 9 12 6 6 8 6 9 12 6 6 8 6 Crankshaft pulley 90 100 66 74 120 130 86 96 280 340 206 250 Injection pump 9 13 6 6 9 6 9 13 6 6 9 6 9 13 6 6 9 6 Bearing bracket rocker...

Page 18: ...mented with 4 pcs pin screws 479971 4 4 pcs nuts 971095 5 4 pcs screws 970964 3 M10x140 4 pcs screws 955311 6 M8x140 4 pcs washers 960148 5 M10 4 pcs washers 960141 0 M8 and the arms from engine fixture 885050 5 9992520 8 Overhaul stand 856927 9 Measuring plastic disposable item 9510060 8 Multimeter 1 8 10 OF 9999179 6 Key for dismantling of fuel and oil filters 885251 9 Adapter for measuring comp...

Page 19: ...ositioning of rating plates Presentation VOLVO a usan asseraBLY PENTA Tx XXXX 1 XXXXXXXXXX 2 XXX XXX 3 XXXX 5 XXXXXXXXXX 6 XXX XXX 7 Engine and transmission decal Design differences engine versions This Workshop Manual applies to all engines MD2010 2040 A B C The most important differences are MD2010 40A MD2010 40B MD2010 40B has Unipolar electrical system The fly wheel cover and the transmission ...

Page 20: ...Presentation 20 2 3 MD201OA B MS2L 17 16 15 14 MD2010A B MS2L 13 ...

Page 21: ...filter 4 Flexible suspension 16 Feed pump with hand pump 5 Starter motor 17 Oil cooler reverse gear 6 Alternator 18 Folding propeller 7 Oil dipstick reverse gear S drive 19 Refrigerant intake S drive 8 Cap for oil dipstick reverse gear S drive 20 Refrigerant cock sea water S drive 9 Fuel filter 21 Oil drain S drive 1 0 Cap for oil replenishment engine 22 Zinc anode zinc ring 11 Oil dipstick engine...

Page 22: ...Presentation 22 6 1 4 2 5 4 MD2010 C MS2L 2 3 MD2020 C 120S 17 16 15 14 MD2010 C MS2L 7 8 9 12 10 11 22 21 MD2020 C 120S 13 ...

Page 23: ...ion 17 Oil cooler reverse gear 5 Starter motor 1 8 Folding propeller 6 Alternator 1 9 Refrigerant intake S drive 7 Oil dipstick reverse gear S drive 20 Refrigerant cock sea water S drive 8 Cap for oil dipstick reverse gear S drive 21 Oil drain S drive 9 Fuel filter 22 Zinc anode zinc ring 1 0 Cap for oil replenishment engine 11 Oil dipstick engine Note When running in freshwater the magnesium anod...

Page 24: ... camshaft gear 24 Engine body Crank mechanism Crankshaft The crankshaft is journaled in three main bearings MD2010 or four main bearings other engines The axial bearing on MD2040 consists of loose thrust wash ers placed at the rear main bearing On the other en gines the rear main bearing cap is made of aluminium and serves as thrust washers The crankshaft is statically and dynamically balanced and...

Page 25: ...gerant temperature relay and sensor where appropriate 8 MD2040 remove the cover at the front on the heat exchanger housing s right hand side Remove the spacer ring thermostat and rubber seal 2 Engine body 11 Release the delivery pipe at the injection pump and injectors Lift off the delivery pipes together Protect the connections from impurities 12 Remove the nut at the top of respective injectors ...

Page 26: ...ts 4 and the lower copper washers 14 Release the electric cable to the glow plug Re move the conductor rail and unscrew the glow plug Fig 12 Dismantling of oil pressure pipe cylinder block cylinder head rocker mechanism 16 Remove the oil pressure pipe between the cylinder block and cylinder head rocker mechanism on MD2040 17 Remove the valve cover built together with the in let pipe on MD2010 MD20...

Page 27: ...se use steel brush to clean the cylin der head screw threads or under the screw heads Engine body I nspection of cylinder head The flatness tolerance for the cylinder head is max 0 12 mm 00472 Check in six positions A F as per Fig 15 and 16 Use a feeler gauge and a ruler the sides of which are precision rubbed as per DIN 874 Normal Fig 15 Checking of cylinder head flatness Fig 16 Checking of cylin...

Page 28: ... 212 F 4 Press the seat in the head Use a hydraulic press 1000 1500 kp 2204 3307 lbf and suitable mandrel 5 Work the seats to the correct angle and width 28 Grinding of valves and valve seats 1 Use a valve spring tensioner and dismantle the valve lock Remove the valve spring washers springs and aloes Place the parts in the correct order in a valve rack Remove the valve stem seals 2 Clean the parts...

Page 29: ...en the cylinder head plane and the valve disc surface A is MD2O10 MD2020 0 70 0 90 mm 0275 0354 in MD2030 MD2040 0 85 1 15 mm 0334 0452 in 7 Grind in the valves with grinding paste and check the contact with marker dye Engine body 8 Fit the seals valves valve springs spring washers valve lock and valve caps See Assembly of cylin der head on page 31 Checking of valve guides Fig 22 Clearance valve v...

Page 30: ... Checking of linearity Place the valve springs on a level surface and check the linearity with a st square Fig 23 Fig 24 Spring tester Place the spring in a spring tester and check its length both compressed and uncompressed The springs should maintain the values given in Tech nical data 30 Fig 25 Dismantling of rocker mechanism MD2040 2 Dismantle the rocker mechanism Remove the rockers springs an...

Page 31: ...inder head Fig 28 Fitting of valve stem seals 1 Press down new valve stem steals on the valve guides Note MD2030 and MD2040 have different seals for the guides for the inlet and outlet valves Engine body 00 C c 2 Fig 29 Fitting of valves 1 Valve lock 3 Valve spring 2 Valve spring retainer 5 Valve cap 4 Valve MD2040 and later versions of MD2O10 2020 2030 2 The valves should be fitted in the correct...

Page 32: ...gram MD2O10 Fig 31 Tightening diagram MD2020 MD2030 MD2040 1st tightening MD2O10 MD2020 10 Nm 7 40 ft lbs MD2030 20 Nm 14 80 ft lbs MD2040 30 Nm 22 10 ft lbs 2nd tightening MD2O10 MD2020 20 Nm 14 80 ft lbs MD2030 35 Nm 25 80 ft lbs MD2040 70 Nm 51 70 ft lbs Final tightening MD2O10 MD2020 35 40 Nm 26 30 ft lbs MD2030 50 53 Nm 37 39 ft lbs MD2040 90 95 Nm 66 70 ft lbs Fig 32 Fitting of the rocker me...

Page 33: ... Tightening torque 20 25 Nm 14 8 18 4 ft lbs 14 MD2O10 MD2020 MD2030 Fit the induction mani fold MD2040 Fit the inlet pipe complete with air filter Fig 35 Fitting of thermostat MD2O10 MD2020 MD2030 and expansion tank 15 MD2O10 MD2020 Fit the rubber seal thermostat 3 and spring 2 in the heat exchanger housing 1 Fig 36 Fitting of thermostat MD2040 17 MD2040 Fit the rubber seal thermostat and spacer ...

Page 34: ...earance for cylinder No 3 and the clearance for the inlet valve on cylinder No 2 Clean the valve cover and fit it Replace the seal if damaged Test run the engine and check that no leakage occurs Dismantling of piston piston rings and connecting rod 1 Empty the cooling system and drain or syphon out the engine oil 2 Dismantle the cylinder head See Dismantling of cylinder head on page 25 and 26 Fig ...

Page 35: ...ndrel I nspection and matching of piston rings Check the wear surfaces and sides Black patches on the surfaces imply poor contact and indicate that it is time to change the piston rings The oil consumption is also a critical factor as to when a piston ring should be replaced Check the piston ring gap Fig 41 Push down the ring below the lower turning position by means of a pis ton Replace the pisto...

Page 36: ...rclip 5 Check that the connecting rod goes easily in the gudgeon pin bearing 38 Check the big end clearance See Inspection of crankshaft and Inspection of main and big end bearings on pages 46 and 47 Check the piston ring gap in the cylinder bore Fig 41 on page 35 and that the rings do not jam in the piston ring grooves Fig 51 Placement of piston rings 1 TOP marking 2 Oil scraper with expander spr...

Page 37: ...D2040 Check that the ends on the expander and scraper rings are in the correct position Fig 52 2 Place the bearing cups in their positions in the con necting rod and cap Check that the hole in the bearing cups comes opposite the hole in the con necting rod Oil in the crank pin with engine oil Engine body Fig 53 Number marking on connecting rod and cap 3 Check that the marking on the piston top alt...

Page 38: ...ling of the timing gear Q WARNING If the crankshaft and camshaft are turned without being synchronised with each other the valves can go against the pistons and be damaged 1 Close the fuel cocks Remove both battery leads 2 Close the bottom valve Release the rubber hoses to the sea water pump and drain out the water in the sea water system 3 Remove the sea water pump 4 Remove the drive belt for the...

Page 39: ...e oil pump 10 Remove the circlip for the intermediate gear Fig 59 Take care of the sleeve washer spring and shims Lift off the gear complete with cover and oil pump 11 Dismantle the crankshaft gear with a universal ex tractor 12 If the camshaft gear is to be dismantled the cam shaft must be removed complete See under head ing Dismantling of camshaft on page 44 I nspection of timing gears Fig 60 Ch...

Page 40: ...gear 3 Fit the thrust washer 9 Fig 62 on the intermedi ate gear s shaft journal Fit the intermediate gear as per the markings Fig 61 NOTE Do not turn the crankshaft before the timing gear casing is fitted 319 4 Fig 62 Intermediate gear complete with oil pump 1 Circlip 7 Spring 2 Spring washer 8 Intermediate gear 3 Spring complete with outer 4 Shims rotor 5 Cover to oil pump 9 Thrust washer 6 Inner...

Page 41: ...jector pump 1 Lock pin 2 Shims 9 Turn the stop lever clockwise and connect the arm to the injection pump Fit the lock pin Engine body NOTE Make sure that the shims which were placed under the injection pump flange are re placed in position before the pump is placed in the cylinder block applicable where the pumps has been removed 10 Tighten the timing gear casing and injection pump Tightening torq...

Page 42: ...ve must be removed together with the camshaft 6 MD2O10 MD2020 Remove the gear for the mechanical tachometer drive Note Mechanical tachometer driving is not used by Volvo Penta The gear must however be in position Inspection of valve lifter and camshaft NOTE If the lifter is worn over the lift surface the lifter must be scrapped The dike shows that the lifter has not rotated A dark stripe on the ou...

Page 43: ...or rect position and tighten it Tightening torque 9 13 Nm 6 6 9 6 ft lbs 4 Fit the regulator sleeve 3 Note The sleeve should engage with the pin on the camshaft gear Note Mechanical tachometers are not used by Volvo Penta but the gear must still be put in position 5 Check that the markings on the timing gear corre spond Fig 58 on page 41 6 Carry out the work as per items 8 to 11 under the heading ...

Page 44: ...g cap from the crankshaft MD2040 Take care of both thrust washers in the rear cap 46 Inspection of crankshaft Clean the crankshaft carefully in all channels after dis mantling and inspect it very carefully to confirm whether it really need renovating 1 2 1 2 Qum Fig 72 Check measurement of crankshaft 1 Check the wear and out of roundness with a mi crometer Measure the diameters A A and B B in item...

Page 45: ...on of main and big end bearings Check the main and big end bearing cups and the front crankshaft busing Replace worn bearings or those with damaged bearing surfaces Inspection of front crankshaft bushing Check the bearing clearance between the big end jour nal and bushing Use a cylinder indicator and a micro meter Fig 74 Checking of bearing clearance 1 Measure the bushing s inner diameter at point...

Page 46: ...the measuring plastic part No 856927 9 as follows Fig 77 Application of measuring plastic 1 Wipe clean the big end bearing and big end journal from oil Cut a piece of measuring plastic to the same length as the bearing width and apply the measuring plastic along the big end journal Fig 77 Note Avoid the oil hole 2 Fit the connecting rod and cap note markings cor respond and tighten the crankshaft ...

Page 47: ...in the bearing and main bearing journals and fit the caps on the crankshaft Note The bevelled edge 1 Fig 79a and 79b should be turned forwards on all caps 4 Fit the cap which is provided with a groove as per 5 2 Fig 79a and 79b Note The bearing cups provided with an oil groove 3 Fig 79a and 79b should be placed in the top cap MD2O10 MD2020 MD2030 Fit aluminium caps with integrated thrust washers a...

Page 48: ...l in the free air 6 Clean the mating surfaces on the flywheel and crankshaft Check the rear crankshaft seal Re place if necessary 7 Fit the flywheel in the correct position guide pin on MD2030 and MD2040 Tightening torque see Technical data 50 Replacement of rear crankshaft seal The seal consists of a rubber ring and becomes access ible after the adapter plate at the back of the flywheel housing t...

Page 49: ... The oil pressure is limited by a reducing valve The valve is placed in the lubricating system just in front of the oil filter and is fitted on the right hand side of the cy linder block in front of the oil filter The valve opens at excessive high pressure and releas es oil back to the sump Crankcase ventilation To prevent overpressure and to separate fuel vapour steam and other gaseous combustion...

Page 50: ... department if the shaft journal for the intermediate gear and oil pump needs to be replaced Fig 84 Checking of oil pump clearance 1 Inner rotor 2 Outer rotor A Max 0 25 mm 0098 in Fitting of the oil pump When fitting the oil pump follow the items 4 10 and 12 17 under the heading Fitting and adjustment transmission on pages 42 44 Replacing the oil filter A WARNING Hot oil can result in burn injuri...

Page 51: ...he regulator sleeve a lever and a regulator arm The speed is regulated over the entire engine speed range from low idling speed to high speed uni versal type Feed pump The feed pump is also positioned on the right hand of the engine and is driven via a cam on the engine s cam shaft Fuel system Injectors The engines are fitted with injectors Fig 86 Each in jector basically consists of a nozzle hold...

Page 52: ...er the injec tion pump flange when the pump is lifted off the cylinder block 4 Send the pump to an authorised diesel workshop for inspection if the workshop does not have spe cially trained personnel with the necessary testing equipment MD2o10 MD2020 MD2030 Nippondenso MD2040 Bosch Fitting of the injection pump Check that the pump is in good condition and if so re quired also tested and approved b...

Page 53: ...ped fuel pipe The pipe makes it easier to see when the fuel begins and stops flowing out from the valve Fig 90 Marking the pulley and engine block 5 Continue turning the crankshaft slowly clockwise until the fuel stops flowing out from the pressure valve holder Check the position of the crankshaft to the marking on the pulley and engine block at this point See Fig 90 If the position is after Y B T...

Page 54: ...he valve holder the pump must be dismantled and the same method applied with the pump in a completely horizontal position 6 Adjustment of the injection angle can also be made by measuring the piston height with a dial gauge The table shows the crankshaft position in degrees when the piston is in a certain position in relation to B T D C Carry out the adjustment work as per items 4 and 5 The table ...

Page 55: ...If necessary adjust to the correct idling speed using the adjustment screw 2 4 Check gap 3 again according to point 1 Engine racing high idling speed Warm up the engine and check the engine racing speed using a workshop tachometer when the engine has no load at wide open throttle WOT see Technical Data for correct engine racing speed Adjust if necessary as follows 1 Slacken off the stop screw 3 so...

Page 56: ...ack or in different compartments Check the nozzle carefully with a lamp magnifier or in a microscope Check the other parts also When fitting a new nozzle it is important that pre serving oil is washed off the nozzle needle and sleeve before the injector is assembled avoid skin contact with needle s slide surface Clean the parts in pure alcohol Check that the nozzle needle slides in the sleeve with...

Page 57: ... must be changed This is done with adjuster washers Fig 103 Note The opening pressure increases or diminishes with approx 1 MPa 10 kp cm 2 142 2 lbf int with a change in the thickness of the adjuster washer by 0 1 mm 0039 in Fuel system Checking of injectors Jet pattern 1 Pump with the nozzle testing device and check the jet pattern The fuel jet should be conformed and in line with the centre line...

Page 58: ...nger As extra equipment the engine can be fitted with a sep arate expansion tank 62 Fig 104 Filler cap for refrigerant Thermostat The engines are provided with a thermostat the sensor body of which contains wax When the engine is cold the thermostat keeps the chan nel to the heat exchanger closed The refrigerant then passes via a a by pass pipe directly back to the induc tion side of the pump As t...

Page 59: ...ose to the drain cock Open the cock and drain out the refrigerant in a vessel Hand in the mixture to a recovery station if it is not to be used again Never pollute the water Fig 105 Draining of the refrigerant Cooling system The sea water system Watch out for the penetration of water in the boat Close the bottom cock or the cock on the S drive Release the cover on the sea water pump and let the wa...

Page 60: ...up coolant if necessary For MD2O10 204OA B the level must be just under the neck of the filler opening and for MD2O10 2040C between the lower edge of the neck of the filler opening and the level spur 1 Reinstall the fill er cap If a separate expansion tank is installed optional extra the level should be between the MAX and MIN marks 64 MD 2010 2040A B Refrigerant level l v ft IN MD 2010 2040C Refr...

Page 61: ... loose deposits in the insert a suit able steel rod can be pushed through the tubes in the opposite direction to the flow of water NOTE Make sure that the rod does not damage the tubes 4 Fit the insert in the heat exchanger NOTE Make sure that the insert is positioned correctly Make sure that the hole in the insert casing comes oppo site the hole in the housing and that the vent hole comes upwards...

Page 62: ...ece plate on the pump with a new gasket Fig 108 Application of sealing compound silicon 3 Apply sealing compound silicon Volvo Penta part No 1161277 7 on the cylinder block as per Fig 108 shaded area Fit the refrigerant pump with a new gasket 4 MD2030 MD2040 Fit the clamp to the alternator 5 Fit the rubber hoses at the pump s inlet and outlet Tighten the hose clips 6 Fit the drive belt It should b...

Page 63: ...l to 68 C 1 154 4 F MD2O10 MD2020 or to 75 C 167 F MD2030 MD2040 3 Submerge the thermostat in the water Check after at least 3 5 minutes that the thermostat is still closed 4 Raise the temperature to boiling point 100 C 212 F Check after 3 5 minutes that the thermo stat has opened at least 6 mm 02362 in MD2O10 MD2020 or to 8 mm 3149 in MD2030 MD2040 Replace the thermostat if these specifications a...

Page 64: ...ature and oil pressure The electrical system is illustrated in two ways The wir ing diagram page 80 shows the wiring cable areas and colours Where respective parts are positioned on the engine is shown in the figures below Positioning of electrical components on the engine Fig 111 Positioning of electrical components on the engine 10 1 Starter motor 8 Fuses 4 pcs 2 Earthing relay A version max 15A...

Page 65: ...ables between alternator and batteries by increasing the charge voltage when necessary from the alternator On delivery from Volvo Penta the sensor system is not activated Connection has however in all probability been carried out in connection with the installation of the engine Electrical system Connection of sensor system 0 Important Stop the engine and then switch off the current with the main ...

Page 66: ...ging current before the charge clamps are re leased WARNING The battery compartment must never be exposed to a naked flame or electrical sparks Never smoke in the vicinity of batteries Hydrogen gas develops during charging which when mixed with air forms oxyhydrogen gas This gas is highly inflammable and very explos ive Always use protective goggles when charging and handing batteries The battery ...

Page 67: ...ced Repair instructions Starting with auxiliary battery 0 WARNING The batteries especially the auxiliary battery contain oxyhydrogen gas which is very explosive A spark which can occur if the auxili ary battery is incorrectly connected is sufficient to cause the battery to explode and result in injury Note If the start battery has frozen it must be thawed first before a start attempt is made with ...

Page 68: ...xceeds this value the lead connections must be rectified as per the Procedure below 74 Procedure A WARNING Disconnect the current and remove both battery leads before working on the charging circuit If the voltage drop during any of the tests as per the items above exceeds 0 2 V the lead connections must be removed and cleaned from oxide etc Spray the con nections with a moisture repellant contact...

Page 69: ...by measuring be tween slip ring and earth Electrical system Dismantling the diode bridge In order to check the diode bridge and stator windings the diode bridge should be dismantled Unsolder the three stator windings Avoid excessive heat since this can damage the diodes Release the nuts note how the washers and nuts are fitted Check measurement of the diode bridge Set the multimeter in the positio...

Page 70: ...ode is defective the entire diode plate must be replaced Check measurement of the stator windings When the diode bridge is removed it is possible to measure the stator windings with the multimeter set to the Buzzer position Measure the resistance between respective windings 76 NOTE Check first the inner resistance in the measuring cables When the measurement between the stator windings is carried ...

Page 71: ...intermediate washer s Fig 116 Dismantling of the bearing shield 4 Remove the rear bearing shield Fig 117 Dismantling of the stator housing 5 Remove the brush holder plate Remove the stator housing from the rotor and front bearing shield on 2040 from the gear housing Fig 118 Dismantling of the rotor 6 Remove the coupling arm and rotor MD2040 The coupling arm is fitted in the gear housing Electrical...

Page 72: ... half of the read value 5 Check the cogs on the starter gear Replace dam aged gear Check also the starter gear ring if the gear is damaged Field winding Check with a test instrument that there is no failure in the winding If the field winding is defective it should be re placed 78 Assembly of the starter motor Assembly is carried out in the reverse order to strip ping Connect and from a 12 V batte...

Page 73: ...ing temperature Sensors Note Sensors are only available with De Luxe instrument panels Oil pressure sensor Fig 125 Oil pressure sensor Resistance testing Measure with falling pressure and with instrument connected Measure with ohmmeter class 1 at 20 C 68 F Electrical system Refrigerant temperature sensor i7 Fig 126 Refrigerant temperature sensor Resistance sensor Measure with the sensor sub merged...

Page 74: ...ed cables are not included from Volvo Penta 1 Battery 9 Glow relay 16 2 Main switch 10 Protective diode 3 Startermotor 11 Fuses 4 pcs max 15A 17 4 Earthing relay 12 Fuses 4 pcs max 15A 18 5 Earth rail 13 Splice 6 Glow plug 14 Oil pressure relay engine normally 7 Alternator open closed at 0 3 bar 0 1 bar 8 Starter relay 15 Oil pressure sensor MD2O10 2 pcs Other engines 3 pcs Cable colours BL Blue O...

Page 75: ... 81 v C 0 n C R25 R25 s8 R Y 2 5 30 87 86 85 6 3 2 1 Battery 7 2 Main switch 8 3 Starter motor 9 4 Alternator 10 5 Glow plug 6 Starter relay 11 Cable colours BL Blue OR Orange LBL Light blue R Red BN Brown SB Black LBN Light brown W White GN Green Y Yellow GR Grey Glow relay 12 Refrigerant temperature relay normally Fuses 4 pcs max 15A open closes at 100 C t2 C 212 F t3 6 F Magnetising resistance ...

Page 76: ...fter the colour code in the wiring diagram Areas not given 1 0 mm 2 ER Instrument lighting Tachometer with built in hour counter accessory alt blind plug Connector for connection of extra warning display accessory Electronics unit alarm Warning lamp refrigerant temperature Warning lamp oil pressure Warning lamp charging Control lamp glowing Switch instrument lighting Switch Alarm test Acknowledgin...

Page 77: ...ing 8 Control lamp glowing 9 Electronics unit alarm 10 Switch instrument lighting 11 Switch alarm test 12 Tachometer 13 Key switch 14 Alarm 15 Connector for connection of neutral position switch accessory 16 2 pole connection for extra panel 17 1 6 pole connection 16 BLISS15 n 1 4 5 6 61 9 8 BUY 1 5 BL BN GN GR OR R SB VO W Y 2 7 4 6 1 5 2 5 4 Cable colours Blue Brown Green Grey Orange Red Black V...

Page 78: ...ssure gauge 4 Refrigerant temperature gauge 5 Connector for connection of extra warning display accessory 6 Electronics unit alarm 7 Warning lamp refrigerant temperature 8 Warning lamp oil pressure 9 Warning lamp charging 10 Control lamp glowing 11 Switch instrument lighting 12 Switch alarm test Acknowledging 13 Tachometer with built in hour counter accessory alt blind plug 14 Key switch 15 Alarm ...

Page 79: ...the crankshaft are adjus ted to the power takeout of the extra equipment R Extra equipment accessories R N 1200 1000 800 700 600 500 400 300 200 0 70 80 90 100 110 120 130 140 150 310 300 290 280 270 260 250 240 230 320 220 330 340 350 0 The following diagram shows the permissible power takeout at a certain positioning of the pulley and extra equipment 210 200 190 180 170 Fig 127 MD 2010 10 20 30 ...

Page 80: ...Notes ...

Page 81: ...f this page write your comments down and post it to us The address is at the bottom of the page We would prefer you to write in English or Swedish From Refers to publication Publication no I ssued Suggestion reasons Date Name AB Volvo Penta Customer Support Dept 42200 SE 405 08 Gothenburg Sweden ...

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Volvo MD2010, Workshop Manual

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