Volvo MD5A Workshop Manual Download Page 31 | Manualshive

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Special tools for the MD5A

Part No

Designation

884538

Drift for pressing out valve guides

884549

Drift for pressing in valve guides

884557

Drift for pressing in injector sleeve.

884541

Tool for removing injector sleeve.

884537

Drift for copper sleeve.

884231
(screw and
nut from
MD21-MD32)

Tool for removing cylinder liner.

884560

Drift for removing rocker arm bush.

884497

Drift for fitting rubber valve seal.

884543

884535

Nipple fixture

Nipple for compression pressure
measurement.

29

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Summary of Contents for MD5A

Page 1: ...Publ No 3061 Dec 1975 WORKSHOP MANUAL MD5A Marine diesel engine ENGINE UNIT ...

Page 2: ...standardized system of measurements In 1960 a decision was made to use a system called SI Systéme International d Unites To a large extent this system is based on earlier systems but the units have been made uniform so that no conversions are necessary The SI system is now being applied within industry in Europe This manual contains the new SI units The units used previously however are also state...

Page 3: ... 12 13 Valve guides nozzle sleeve 14 15 Valves valve seats rocker mechanism injector 15 16 Hand start mechanism camshaft 17 Assembling Cylinder liner crankshaft 18 Cylinder camshaft governor 19 Lubricating oil pump transmission cover 20 Adjustment of control rod travel assembling flywheel cover 20 21 Oil sump cylinder head feed cover 22 Fuel filter injector thermostat 22 Flywheel generator valve a...

Page 4: ...4 Decompression lever 5 Injector 6 Oil filler Cap engine 7 Water drain tap gearbox 8 Oil drain plug gearbox 9 Water drain tap engine 10 Oil filler gearbox 11 Sea water pump 12 Dipstick gearbox 13 Fuel filter 14 Bleed screw 15 Hand pump fuel 16 Dipstick engine 17 Oil filter 2 ...

Page 5: ...ear Note Pull the rocker gear straight up since it is centred with a guide pin 1 The other hole 2 is an oil channel 2 Remove the generator and its drive belt starter motor fuel filter and fuel pump with the drain off pipe be careful of fuel spillage coolant water pump with hose and thermostat housing dipstick temperature and oil pressure sensors Unscrew and discard the oil filter 4 Remove the push...

Page 6: ...spokes 7 Remove the cover for the injection pump Note The bracket for the cold start is fixed with one of the screws Take care of the spring under the cover 6 Fit tool 884078 to the flywheel Afterwards screw in the centre screw on the tool until the flywheel loosens 8 Prise the lower ball joint free from the pump with a screwdriver 4 ...

Page 7: ...nd the gear wheel can then be withdrawn 10 Remove the sump and then the transmission cover 13 screws The lifting eye is fixed one of the screws The cover is centralised by guide pins 12 Remove the screw and the locking washer for the gearbox drive flange on the crankshaft and remove the flange with a puller Use counter force Remove the key afterwards 5 ...

Page 8: ...side 4 screws Then remove the camshaft and the gearwheel 14 Remove the cover flywheel side 10 screws The cover is centred with guide pins The screws by the guide pins are fitted with thick washers 16 Mark and remove the bearing cap on the crankshaft and carefully knock out the piston through the cylinder 6 ...

Page 9: ...ssion side Lift the crankshaft out and the bearing shells afterwards and then the axial bearing halves 18 Mark the cylinder liner s position in the cylinder so that the same position can be obtained during assembly Remove the cylinder liner Use tool 884551 Use the long screw and its nut from the tool 884231 MD21 MD32 See page 29 Special tools Discard the 0 ring Afterwards remove the 0 rings in the...

Page 10: ...ove the gearwheel from the housing Remove the split pin for the reduction valve Remove washer 1 spring 2 and piston 3 Clean and replace damaged parts Assemble the lubricating oil pump in the reverse order Note Fit a new gasket 4 between the housing and the cover Fix the wire mesh 5 in position with the steel wire 6 and finally lay the key in position and tighten the gearwheel 7 24 Remove the cover...

Page 11: ...sket on the cover and tighten the cover with the six screws 25 Unscrew the screw and withdraw the impeller from the shaft If the sealing rings are to be replaced the shaft and the impeller can be removed and the screw subsequently loosened 26 Remove the sealing rings 1 and the 0 ring 2 earlier engines and clean the housing and the shaft Note The pump must be removed from the engine Check that ther...

Page 12: ...Then remove the diaphragm from the housing 30 Remove the six screws which hold the upper and lower pump halves together Remove the pump s spring and undo screw 2 which holds the pump arm spindle 32 Remove screw 1 and withdraw the manual pump arm 2 and replace spring 3 if it is broken Note Be careful of the rubber seal which is pressed into the housing 10 ...

Page 13: ... Crankshaft 35 Remove the circlip with circlip pliers Then remove the gear drive Use a press or a gear puller Clean the crankshaft and carry out control measurements of all the bearing surfaces Grind the shaft where necessary See technical data Fuel filter 34 When the filter insert is changed the centre screw 1 is removed allowing the filter holder to be removed Afterwards remove the filter insert...

Page 14: ...s move easily lubricate and refit them in the reverse order 39 Mark the piston and the connecting rod Remove the circlips Press out the gudgeon pin with a drift The piston can be heated first to ease removal Piston 38 Remove the piston rings with the help of piston ring pliers Clean the piston and be particularly careful about the piston ring grooves 40 Press the bush out of the connecting rod if ...

Page 15: ...ing in the lowest groove The oil scraper ring can be fitted either way Continue with the compression ring which is marked TOP on one side This marking shall face upwards when fitted The piston ring with the chromium insert is fitted last and can be fitted either way Cylinder head 44 Remove the collets the collars and the valve springs with the help of a valve spring compressor Remove the valves Re...

Page 16: ...yoke onto the studs which hold the nozzle Screw on the nut and tighten until the sleeve is removed 46 New valve guides are fitted with tool 884549 Use a press This tool gives the guide the right height above the cylinder head s valve spring seat surface Check the dimen sion A this must be 9 mm 0 3543 in when the guide is pressed into place 48 Remove the 0 ring which provides a seal between the sle...

Page 17: ...m 0 0984 in Note If this dimension is exceeded even if a new valve is fitted the cylinder head must be changed 49 Lubricate the mandrel tool 884537 and insert the tool into the sleeve Ensure that the centre screw is sufficiently unscrewed Place some nuts or several washers on the studs so that the yoke can be tightened in place with the fixing nuts Screw in the mandrel as far as the mating face of...

Page 18: ...e fuel spray discontinues simultaneously at all four holes and that no subsequent drops appear Adjustment of opening pressure 56 The opening pressure is adjusted with adjustment washer 1 which is available in thicknesses between 1 mm 0 0394 in l and 1 95 mm 0 0768 in with a difference of 0 05 0 0020 in mm between each size Dismantle the nozzle and replace the washer with a thinner or thicker washe...

Page 19: ...mshaft must be changed as well A new camshaft gear cannot be fitted to an early type of camshaft Furthermore this means that the transmission cover must be machined since the new camshaft gear is thicker than the earlier gear and consequently there is not enough space for it in the transmission cover The axial guide face distance A must be filed down by 3mm 0 1181 in If the camshaft is damaged thi...

Page 20: ... the oil grooves 1 outwards 64 Oil both the bearing halves and place the crankshaft in position Fit the main bearing shells in the bearing housings and place the axial bearings with the oil grooves outwards Fit the bearing housing so that the indentation in the housing faces the same way as the indentation in the bearing half already in the block Tighten the bearing housing with a torque of 70 Nm ...

Page 21: ...on crown faces the nozzle side 67 Fit the camshaft with the camshaft gear Align the marks on the crankshaft gear and the camshaft gear 66 Oil and fit the big end bearing shells in the bearing half Turn mark to the correct position and fit the bearing half Tightening torque 70 Nm 7 kpm 50Lbft 68 Fit the governor Tighten it in position with the set screw on the side See that it goes into the groove ...

Page 22: ... on the ball end of the control arm Measure and check that the control rod travel is correctly adjusted The same as prior to dismantling The measurement must be carried out with a new gasket Set the control at full throttle Press down the plunger to bottom position Note that the cold start must not be engaged during measurement The exact amount injected can only be determined when checking in a te...

Page 23: ...an be loosened and the adjusting screw can be adjusted until the engine runs smoke free See the technical data for the correct injection amount 74 Measure the adjusting screw s length and adjust any eventual deviation so that the plunger stops when released 8 mm Screw down the cover afterwards 76 Fit a new gasket and fit the flywheel cover Be careful so that the sealing ring is not damaged Trim th...

Page 24: ... cylinder head gasket and then the cylinder head Place the washers under the nuts and tighten the nuts in three stages to 70 Nm 7 kpm 50Lbft See the tightening sequence First stage 10 Nm 1 kpm 7Lbft Second stage 40 Nm 4 kpm 29Lbft Third stage 70 Nm 7 kpm 50Lbft 80 Lubricate the oil filter rubber seal Screw in the oil filter so far that the rubber seal first contacts the engine body Afterwards scre...

Page 25: ...es of the pipe unions Thermostat testing 84 Lower the thermostat into hot water and check with a thermometer if the thermostat opens and closes correctly at the right temperature It should start to open at 60 0 C 140 0 F and should be fully open at 90 0 C 194 0 F If the thermostat is defective it must be replaced Clean the thermostat and fit a new gasket 1 Place the thermostat in the engine and fi...

Page 26: ...lt tensioner Fit and tension the drive belt so that it can be depressed 3 4 mm 0 1181 0 1575 in with normal thumb pressure Tappet adjustment 88 Turn the flywheel until both tappets function Turn the flywheel a further complete turn and adjust the tappets The clearance is 0 30 mm 0 0118 in for the inlet valve nearest flywheel and 0 35 mm 10 0138 in for the exhaust valve when the engine is hot Fit t...

Page 27: ...ttom Turn the engine in the rotation direction until compression is felt 90 Rotate the engine in the correct direction until the level tube 1 is full with air free fuel 92 If the injection angle does not meet the prescribed value the number of washers 1 between the pump housing and the transmission cover is increased or decreased until the correct value is obtained One washer gives a difference in...

Page 28: ...uit between the alternator and the battery when the engine is running If a main switch is fitted it must therefore not be turned off until the engine is stopped No lead must be disconnected when the engine is running since this can irreparably damage the charging regulator 2 The battery battery cable and cable terminals are to be checked regularly The battery poles are to be properly clean and the...

Page 29: ...een 0 75 18 K Blue Yellow 0 75 18 L White Red 0 75 18 M Blue Red 0 75 18 Circuit explanation 1 Extra switch 2 Charging control lamp 3 Temperature warning lamp 4 Oil pressure warning lamp 5 Key switch 6 Warning unit 7 Screw 8 Charging control lamp for secondary battery circuit extra equipment 9 Place for instruments extra equipment 10 Snap connection 11 Starter motor 12 Alternator 13 Fusebox 14 Mai...

Page 30: ...clean the pre filter in diesel oil Refit the filter with the notches upward and fit an undamaged packing and tighten the cover Bleed the fuel system Check and drain when necessary the extra fuel filter if one is fitted Look out for spilled fuel C Check the injector with reference to opening pressure tightness and jet shape It is recommended that these checks be carried out after a maximum operatio...

Page 31: ...ft for pressing in injector sleeve 884541 Tool for removing injector sleeve 884537 Drift for copper sleeve 884551 884231 screw and nut from MD21 MD32 Tool for removing cylinder liner 884560 Drift for removing rocker arm bush 884497 Drift for fitting rubber valve seal 884543 884535 Nipple fixture Nipple for compression pressure measurement 29 ...

Page 32: ...Axial clearance end float mm in Main bearings radial clearance mm in Big end bearing radial clearance mm in Main bearing journals Diameter standard mm in Diameter undersized 0 250 mm in Diameter undersized 0 500 mm in Main bearing shells Thickness standard mm in Oversized 0 250 mm in Oversized 0 500 mm in 1 Measured with a Moto Meter nipple 884535 and fixture 884543 MD5A 5 5 kW 7 5 b h p 1 84 mm 3...

Page 33: ...m in Loaded with a force of 300 N 30 kp 66 lb mm in Lubrication system Engine oil capacity ex filter Imp qts US qts Engine oil capacity inc filter Imp qts US qts Oil quality according to API system 1st alternative Above 10 0 C 5Q0 F Volvo Penta oil Double grade Below 10 0 C 50 0 F Volvo Penta oil Single grade 2nd alternative Viscosity above 10 0 Cj50 0 F Viscosity below 100 50 F Oil pressure hot e...

Page 34: ...0 F Fully open at 0 C 0 F WEAR TOLERANCES Cylinders liner Replaced when worn or if the engine has an abnormally high oil consumption mm in Crankshaft Main and big end bearings Permissible ovality mm in Permissible conicity mm in Max axial clearance end float mm in Camshaft Bearing journals permissible ovality tom in Max clearance between camshaft and bearings mm in Valves Max clearance between val...

Page 35: ...ings Nuts for injector holder 70 Nm 7 kpm 50Lbft 20 Nm 2 kpm 14Lbft 80 Nm 8 kpm 58 Lbft 500 Nm 50 kpm 362Lbft 70 Nm 7 kpm 50Lbft 60 Nm 6 kpm 43Lbft 70 Nm 7 kpm 50 Lbtt 10 Nm 1 kpm 7Lbft Tightening torque for cylinder head nuts Note The tightening must be done in three stages First stage 10 Nm 1 kpm 7Lbft Second stage 40 Nm 4 kpm 29Lbft Final stage 70 Nm 7 kpm 50Lbft 33 ...

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