Volvo MD2010 Workshop Manual
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Volvo MD2010 Workshop Manual

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MD2010, MD2020, MD2030, MD2040

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Summary of Contents for Volvo MD2010

  • Page 1 Workshop Manual Engine MD2010, MD2020, MD2030, MD2040...

  • Page 2: Table Of Contents

    Workshop Manual Marine engines MD201OA/B/C MD202OA/B/C MD203OA/B/C MD204OA/B/C • • • Contents Technical data Repair instructions I njection pump I njection pump Wear tolerances Adjustment of injection angle Adjustment of speed Tightening torque Feed pump Fuel filter Special tools Bleeding of fuel system I njector Presentation Checking of injector...

  • Page 3: Safety Precautions

    Volvo Penta products or product types described in the Table of Contents. Check that you have the correct Workshop Manual for your engine.
  • Page 4 Always use protective glasses or goggles when Ensure that rags soaked in oil or fuel and used fuel or oil filters are stored safely. Rags soaked carrying out work where there is a risk of splin- ters, grinding sparks, acid splashes or where i n oil can spontaneously ignite under certain cir- other chemicals are used.
  • Page 5 The product must comply with the approved example on certifica- tion. For Volvo Penta as the manufacturer to be able ac- cept responsibility for the compliance of engines in use with the set environmental requirements, the following...

  • Page 6: Wear Tolerances

    Volvo Penta AB can only Bear in mind that most of the chemicals used around i ndicate the risks considered likely to occur as a result boats are harmful to the environment if used incorrectly.
  • Page 7 I n 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.
  • Page 8 Safety rules for fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings for shafts, and in O-rings, for example. When fluorocarbon rubber is subjected to high tem- peratures (above 300°C/572°F), hydrofluoric acid can be formed, which is highly corrosive. Skin con- tact can give severe chemical burns.

  • Page 9: Technical Data

    General MD2010 MD2020 MD2030 Engine designation M D2040 Number of cylinders Cylinder diameter 67 mm 67 mm 75 mm 84 mm (2.637 in) (2.637 in) (2.952 in) (3.307 in) Stroke length 64 mm 64 mm 72 mm 90 mm (2.519 in) (2.519 in) (2.834 in) (3.543 in)
  • Page 10 MD2010 M D2030 M D2040 M D2020 Piston ring gap in cylinder measured in mm, top compression ring 0.13-0.25 0.15-0.27 0.20-0.35 (.0051-.0098 in) (.0059-.0106 in) (.0078-.0137 in) 2nd compression ring 0.10-0.22 0.12-0.24 0.20-0.40 (.0039-.0118 in) (.0047-.0094 in) (.0078-.0157 in) Oil ring 0.10-0.30 0.20-0.35 0.20-0.40...

  • Page 11: Main Bearing Journals

    Main bearing Main bearing journals MD2010 MD2020 Diameter in mm, standard, bearing journal No. 1 i n) i n) i n) i n) i n) undersize, No. 1 i n) i n) i n) i n) i n) i n) undersize, No.

  • Page 12: Connecting Rods

    Big-end bearing shells MD2010 , MD2020 MD2030 , MD2040 Thickness in mm, standard i n) i n) oversize i n) i n) i n) mm ......i n) i n) i n) Connecting rods MD2010, MD2020 M D2030 M D2040 Fitted with replaceable bearing shells.

  • Page 13: I Njection Pump

    Valve springs MD2010 MD2020 MD2030 MD2040 Length in mm (in) uncompressed 33(l.299) 33(l.299) 35(l.377) 35(l.377) with 79.4 N (58.56 ft.lbf) compression 30.4 (1.196) 30.4 (1.196) with 67.7 N (49.93 ft.lbf) compression 28.3 (1.114) 28.3 (1.114) Push rods Length in mm (in), total 195.8-196.2 (5.748) (5.748)

  • Page 14: Starter Motor

    Injector MD2010 MD2020 MD2030 MD2040 Opening pressure (checking) 11.3-12.3 MPa 11.3-12.3 MPa 11.3-12.3 MPa 15.2-16.2 MPa 115-125 kp/cm 115-125 kp/cm 115-125 kp/cm 155-165 kp/cm 1639-1784 lbf/in 1639-1784 lbf/in 1639-1784 lbf/in 2205-2347 lbf/in Opening pressure (adjustment) 11.8 MPa 11.8 MPa 11.8 MPa 15.7 MPa 120 kp/cm 120 kp/cm...

  • Page 15: Wear Tolerances

    Note: Unless otherwise stated the given values refer to all engines. General Compression pressure at starter motor speed (min. 200 rpm) ..min. 25 kp/cm (355.6 lbf/int) Pistons Piston clearance max. 0.25 mm (.0098 in) Piston rings Piston ring clearance in groove: Compression rings max.
  • Page 16 Crankshaft Curvature max. 0.06 mm (.00236 in) Connecting rods Linearity, deviation on 100 mm (3.937 in) measured length max. 0.15 mm (.00590 in) Distortion on 100 mm (3.937 in) measured length max. 0.2 mm (.00787 in) Axial clearance, crankshaft - connecting rod max.

  • Page 17: Tightening Torque

    MD2010 M D 2030 M D2040 M D 2020 Cylinder head* Main bearing: top to bottom bearing cap (steel) (aluminium) Main bearing cap to cylinder block Big-end bearing End-plate/flywheel housing Flywheel housing Flywheel Flexible coupling Adapter plate for flywheel housing Suction strainer, oil pump Bottom plate Sump...

  • Page 18: Special Tools

    Note. If necessary, the workshop should be equipped with 2 deep (minimum 80 mm) hexagonal sockets, 22 mm and 27mm, for removing the injectors. These sockets can be obtained from a well stocked tool supplier and are not stocked by Volvo Penta. 885224-6 Engine fixture.

  • Page 19: Presentation

    • Deeper and narrower oil sump • Reinforced generator mountings for 2010 and 2020 • Common oil filter for 2010-40 Positioning of rating plates VOLVO a,usan asseraBLY •x vxUYeo ~x nCCOXnnxR' i0 PENTA XXXXXXX nvvxoR ( 4)
  • Page 20 16 15 MD201OA/B & MS2L MD2010A/B & MS2L...
  • Page 21 MD203OA/B & MS2A MD203OA/B & MS2A MD204OA/B & MS2L 1. Cap for replenishing of refrigerant 13. Sea water pump 2. Expansion tank 14. I njection pump 3. Relay box with fuses 15. Oil filter 4. Flexible suspension 16. Feed pump (with hand pump) 5.
  • Page 22 Presentation 16 15 MD2010-C & MS2L MD2010-C & MS2L 9 12 10 11 MD2020-C & 120S MD2020-C & 120S...
  • Page 23 MD2030-C & MS2A MD2030-C & MS2A 8 12 10 11 MD2040-C & MS2L MD2040-C & MS2L 1. Cap for replenishing of refrigerant 14. I njection pump 2. Expansion tank 15. Oil filter 3. Relay box with fuses 16. Feed pump (with hand pump) 4.

  • Page 24: Engine Body

    Description Crank mechanism Crankshaft Cylinder head The crankshaft is journaled in three main bearings ( MD2010 ), or four main bearings (other engines). The The cylinder head is manufactured of specially alloyed axial bearing on MD2040 consists of loose thrust wash- cast iron.

  • Page 25: Repair Instructions Cylinder Head

    Repair instructions Cylinder head Dismantling of cylinder head Remove both battery leads. Close the fuel cocks. Close the bottom valve and drain off the water in the sea and fresh water system. Release the hose to the heat exchanger from the sea water pump.
  • Page 26 11601 MD2010 , -2020 M D2030 M D2040 Fig. 10. Dismantling of injectors 1. Injector 3. Heat shield ( MD2030 ) Fig. 12. Dismantling of oil pressure pipe (cylinder 2. Copper gasket 4. Insert (MD2010-2030) block - cylinder head/rocker mechanism) 13.
  • Page 27 Stripping of cylinder head 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.
  • Page 28 Replacement of valve seat Grinding of valves and valve seats 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. Clean the parts.
  • Page 29 Check the wear on the valve guides (see "Check- Fit the seals, valves, valve springs, spring washers, i ng of valve guides") before the valve seats are valve lock and valve caps. See "Assembly of cylin- treated. der head" on page 31. °...
  • Page 30 Checking of valve springs Renovating the rocker mechanism Check that the springs do not show any signs of MD2O10, MD2020, MD2030: Remove the screws damage. at the front and rear of the rocker shaft. MD2040: Screw in a M8 screw in the threaded hole i n the front edge of the rocker shaft.
  • Page 31 Fitting of cylinder head Fig. 27. Clearance rocker - rocker shaft Fig. 28. Fitting of valve stem seals Check that the rocker bearing surfaces are not out- Press down new valve stem steals on the valve of-round worn. guides. Calculate the clearance between the rocker and Note: MD2030 and MD2040 have different seals shaft.
  • Page 32 Fitting of cylinder head 1st tightening MD2O10. MD2020 10 Nm (7.40 ft.lbs) Clean the surface of the cylinder head and cylinder MD2030 20 Nm (14.80 ft.lbs) block. Remove any rust or soot from the screw ho- MD2040 30 Nm (22.10 ft.lbs l es and threads for the cylinder head screws.
  • Page 33 MD2O10, MD2020: Fit the circulation pump. V& MD2030: Fit the circulation pump and thermostat and spring (see Fig. 35). 10. Fit the glow plug, Tightening torque: see Technical data. Fit the conductor rail and connect the electric cable. Fig. 35. Fitting of thermostat (MD2O10, MD2020, MINK MD2030) and expansion tank.

  • Page 34: Connecting Rod

    19. Fit the relay box. MD2020. MD2030. MD2040: Check and adjust if necessary the valve clearance for cylinder No. 1, 20. MD2O10, MD2020: Fit the alternator and clamp. Fit and the clearance for the outlet valve on cylinder the drive belt. No.
  • Page 35 Turn round the crankshaft until the piston in ques- tion is in the lower turning position. Dismantle the Check the wear surfaces and sides. Black patches on main bearing cap with lower bearing cup. the surfaces imply poor contact and indicate that it is ti me to change the piston rings.
  • Page 36 Assembly of piston, piston rings and connecting rod Check the big-end clearance. See "Inspection of crankshaft" and "Inspection of main and big-end Note: Check that pistons of the correct oversize are bearings" on pages 46 and 47. used if the cylinders have been milled to oversize. Check the piston ring gap in the cylinder bore (Fig.
  • Page 37 MD2040: Place the expander (2, Fig. 52 on page 38) to the oil scraper rings in the piston ring groove. Check that the ends on the expander do not over- l ap each other. Fit the top scraper ring (1) over the the expander.
  • Page 38 Dismantling of the timing gear Timing gears Replacement of front crankshaft seal WARNING! If the crankshaft and camshaft are turned without being synchronised with each other the valves can go against the pistons and be damaged. The seal consists of a rubber ring and can be replaced after the crankshaft pulley has been removed.
  • Page 39 Fig. 59. Dismantling of circlip to cover for the oil pump Fig. 57. Dismantling of injection pump 10. Remove the circlip for the intermediate gear 1. Lock pin ( Fig. 59). Take care of the sleeve washer, spring 2. Shims and shims.
  • Page 40 Fitting and adjustment WARNING! I f the crankshaft and camshaft are turned without being synchronised with each other the valves can go against the pistons and be damaged. Note: The gears in the timing gears which are of import- ance for adjustment are marked as follows: Crankshaft gear - the intermediate gear is marked with a punch mark and the intermediate gear - camshaft Fig.
  • Page 41 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 torque: see Technical data.

  • Page 42: Camshaft

    Connect the water hoses to the pump. mechanical tachometer drive*. 15. Fit the drive belt to the alternator. * Note: Mechanical tachometer driving is not used by Volvo Penta. The gear must, however, be in position. Note: If the tension is correct the belt should be able to be pressed in approx.
  • Page 43 Note: If parts have been replaced on the camshaft the * Note: Mechanical tachometers are not used by . fitting of these should take place in the order shown in Volvo Penta, but the gear must still be put in Fig. 69. position.

  • Page 44: Crank Mechanism

    Crank mechanism Inspection of crankshaft Dismantling of crankshaft Clean the crankshaft carefully in all channels after dis- mantling and inspect it very carefully to confirm whether (engine removed) it really need renovating. Dismantle the reverse gear alt. S-drive and adapter plate and coupling, flywheel and flywheel housing.
  • Page 45 Grinding of the crankshaft I nspection of front crankshaft bushing To achieve satisfactory results in connection with grind- ing the following factors should be taken into considera- Check the bearing clearance between the big-end jour- tion: nal and bushing. Use a cylinder indicator and a micro- meter.
  • Page 46 Replacement of front crankshaft bushing Check that the oil channel is open after pressing in. Check also the bushing's inner diameter. See Dismantle the bushing from the cylinder block. "Technical data" for size. Check that the bushing's mating surface in the block has no burrs or upset ends.
  • Page 47 Fig. 78. Check measuring of measuring plastic Remove the cap and measure the width on the pressed out measuring plastic at the widest point. Fig. 79a. Fitting of main bearing cap MD2O10, Use the scale which accompanies the measuring MD2020, MD2030 plastic (Fig.
  • Page 48 Replacement of rear crankshaft seal Tighten the main bearing cap. Tightening torque, see Technical data. The seal consists of a rubber ring and becomes access- i ble after the adapter plate at the back of the flywheel housing, the flexible coupling, flywheel* and flywheel housing have been removed.

  • Page 49: Lubricating System

    General Oil filter The engines are provided with a pressure lubricating The oil filter is of the full flow type which implies that all system with an oil filter of the full flow type. the oil is filtered before it is pressed out to the bearing areas.

  • Page 50: Replacing The Oil Filter

    (Fig. 84). Max. permissible clearance brush. 0.25 mm (.0098 in). Note. Contact Volvo Penta service department if the shaft journal for the intermediate gear and oil pump needs to be replaced.

  • Page 51: Fuel System

    General Injectors The fuel is induced by the feed pump from the fuel tank The engines are fitted with injectors (Fig. 86). Each in- through a water separating pre-filter (accessory) and j ector basically consists of a nozzle holder and a pressed through the fine filter to the injection pump nozzle.

  • Page 52: Adjustment Of Injection Angle

    Repair instructions Send the pump to an authorised diesel workshop* for inspection if the workshop does not have spe- Observe the greatest possible cleanliness when work- cially trained personnel with the necessary testing i ng with the fuel system. equipment. 'MD2o10, MD2020, MD2030: Nippondenso.

  • Page 53: Adjustment Of Injection Angle

    Adjustment of injection angle Use a scrapped fuel pipe. The pipe makes it easier to see when the fuel begins and stops flowing out Fit the injection pump as per the previous section with from the valve. the exception of item 1 which is changed to item 1 be- low.
  • Page 54 Note: A change of shim size by 0.1 mm (.0039 in) implies that the injection start is moved approx. 1 °. An increase in shim size reduces the injection angle and conversely a decrease in shim size in- creases the angle. Shims are available in the following sizes: 0.2, 0.3, 0.4 and 0.5 mm (.0078, .0118, .0157 and .0196 in).

  • Page 55: Feed Pump

    Fuel Setting engine speed (RPM) Warm up the engine and check the idling speed using a workshop tachometer (see Technical Data Check that the throttle mechanism functions normally. for correct idling speed). Check that the throttle arm (1) (Fig. moves towards low idle (2) when the throttle mechanism is in idling position and moves towards the stop screw at wide open throttle If necessary, adjust to the correct idling speed...

  • Page 56: 1. Injector

    I njectors Fit the fuel leak pipe. Replacement of injectors Fit the delivery pipes. Check that they do not come Wash clean round the injectors. skew, and tighten the nuts. Release the delivery pipes at the injection pump Tightening torque: 20-25 Nm (14.7-18.4 ft.lbs). and at the injectors.

  • Page 57: Checking Of Injector

    Testing of injectors Checking of injectors Testing is carried out in a nozzle testing device. The Jet pattern opening pressure and tightness are the most important Pump with the nozzle testing device and check the part of the test. The jet pattern is more difficult to evalu- j et pattern.

  • Page 58: Cooling System

    General Sea water pump The engines are fresh water cooled and fitted with an The sea water pump is fitted on the timing gear housing at the front end of the engine. The pump is driven via the enclosed cooling system. The system is divided into t wo circuits.

  • Page 59: Repair Instructions

    The refrigerant has the twin purpose of protecting the cooling system from freezing and preventing corrosion. Antifreeze Use a mixture of 50 % Volvo Penta antifreeze (glycol) and 50 % pure water (as neutral as possible). This mixture prevents freezing down to approx. -40°C (-40°F) and should be used all year round.
  • Page 60 Replenishment of refrigerant Flush the cooling system before filling up with re- frigerant. Close all the drain points and fill up with refrigerant to the correct level. See next page. Filling should be done with an idle engine. The en- gine must not be started before the system is vented and completely filled.
  • Page 61 Checking of pressure valve in filler cap Release the hose clips and remove the rubber muffs at the front and back of the heat exchanger. Pull out the insert. Drain off the refrigerant and connect the pressure testing device with a nipple to one of the plugged Flush and clean the insert inside and outside.

  • Page 62: Circulation Pump

    Fig. 108. Application of sealing compound (silicon) Release the electric cables to the temperature re- l ay. 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.

  • Page 63: Replacing The Thermostat

    MD2O10-2020 M D2040 Fig. 109. Replacing the pump wheel Pull and twist out the pump wheel (impeller) with a M D2030 pair of universal pliers. Fig.110. Positioning of the thermostat 1. Cover Clean the housing internally. Grease in the pump housing and inside of the cover with a little grease.

  • Page 64: Electrical System

    Electrical system The electrical system also includes as accessories re- General l ays for the monitoring of the engine's refrigerant tem- The engines are fitted with AC generators. The system perature and oil pressure. voltage is 12V. The electrical system is illustrated in two ways. The wir- MD2010A, -2020A, -2030A and -2040A are fitted with a i ng diagram (page 80) shows the wiring, cable areas 1,5-pole* electrical system, while MD201OB/C, 2020B/...
  • Page 65 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.

  • Page 66: I Mportant Info

    Volvo Penta charging dis- Permissible extra outlets are a total of max. 5A tributor to the standard alternator (accessory).

  • Page 67: Galvanic Corrosion

    Galvanic corrosion Electric welding MD201OB/C, MD2020B/C, MD203OB/C, MD204OB/C Remove the plus and minus leads from the batteries, and then remove all cables to the alternator. The engine's flywheel housing and transmission (re- verse gear/S-drive) are electrically insulated from the Always connect the welding clip to the component engine.

  • Page 68: Alternator

    Conduct test as follows: be removed and cleaned from oxide etc. Spray the con- Connect the multimeter between the alternator's B+ and nections with a moisture repellant contact oil (Volvo B- connections. Universal oil, part. No. 1161398-1) or the like and tight- en the connection again.
  • Page 69 Checking of the regulator Dismantling the diode bridge I n order to check the diode bridge and stator windings the diode bridge should be dismantled. Check before testing that the instrument's batteries Unsolder the three stator windings. Avoid excessive have the correct voltage. Press in the button "Test" and heat since this can damage the diodes.
  • Page 70 Check the 13- diodes in the opposite direction of current NOTE! Check first the inner resistance in the measuring flow by switching the position of the positive and neg- cables. When the measurement between the stator ative probes. Carry out the same measurement proced- windings is carried out the measuring cable's inner re- ure as above.
  • Page 71 Dismantling of the starter motor Remove both battery leads. Release the electric cables to the starter motor. Dismantle the starter motor's attachment screws and lift off the starter motor. Stripping of the starter motor Fig. 117. Dismantling of the stator housing Clean the exterior of the starter motor.

  • Page 72: Electrical Components

    Inspection of the starter motor Assembly of the starter motor Assembly is carried out in the reverse order to strip- ping. Connect + and - from a 12 V battery to the terminal on the magnet and check that the starter gear is pushed forward to the gear stop.
  • Page 73 Relays Sensors Oil pressure relay - alarm Note: Sensors are only available with "De Luxe" i nstrument panels. Oil pressure sensor Fig. 122. Oil pressure relay Contact type: Normally open. The contacts close if the oil pressure in the engine drops below 0.3 ± 0.15 bar (4.18 t 2 psi).
  • Page 74 LBN = Light brown White GN = Green Yellow GR = Grey Cable areas in mm are given after the colour code in the wiring diagram. Areas not given = 1.0 mm Dashed cables are not included from Volvo Penta.

  • Page 75: Wiring Diagram

    LBN = Light brown White Yellow GN = Green GR = Grey are given after the colour code in the wiring diagram. Cable areas in mm Areas not given = 1.0 mm Dashed cables are not included from Volvo Penta.
  • Page 76 Instrument panel, alternative "B" MD201OB/C, MD2020B/C, MD2030B/C, MD204OB/C I ®® 0 0 (9 (9 rFr>P • - 12 W/S8 Return spring I nstrument lighting Tachometer with built-in hour counter (accessory), alt. blind plug Connector for connection of extra warning display (accessory) Electronics unit (alarm) Return spring...
  • Page 77 I nstrument panel, alternative "C" MD2010A, MD2020A, MD2030A, MD2040A SB 1 0 Return spring $ 15a15b 305019 1. I nstrument lighting BLISS15 n© 2. Voltmeter BUY 1.5 12 13 14 15 3. Oil pressure gauge 4. Refrigerant temperature gauge 5. Warning lamp, refrigerant temperature 6.
  • Page 78 Wiring diagram Instrument panel, alternative "C" MD2010B/C, MD2020B/C, MD2030B/C, MD204OB/C . A- avw is atir 12 13 1. I nstrument lighting 2. Voltmeter 3. Oil pressure gauge 4. Refrigerant temperature gauge Return spring 5. Connector for connection of extra warning display (accessory) 6.

  • Page 79: Extra Equipment

    Extra equipment which is driven with V-bet*,s via the The following diagram shows the permissible power engine's crankshaft result in an increased load on the takeout at a certain positioning of the pulley and extra crankshaft. It is therefore important that the axial posi- equipment.
  • Page 80 Notes ................~ ................................................................................................................................................................................................................................................................................
  • Page 81 The address is at the bottom of the page. We would prefer you to write in English or Swedish. From: .................................... Refers to publication: I ssued: ..Publication no.: Suggestion/reasons: ............................................................................................................................................Date: Name: AB Volvo Penta Customer Support Dept. 42200 SE-405 08 Gothenburg Sweden...

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