Volvo Penta Manual (EN)

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Workshop Manual Engine A 2(0) MD2010, MD2020, MD2030, MD2040

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Workshop Manual Marine engines MD201OA/B/C MD202OA/B/C MD203OA/B/C MD204OA/B/C Contents Technical data Repair instructions 9 I njection pump 54 I njection pump Wear tolerances 15 Adjustment of injection angle 55 Tightening torque 17 Adjustment of speed 57 Feed pump 58 Special tools 18 Fuel filter 59 Bleeding of fuel system 59 I njector 60 Presentation Checking of injector 61 Description of engine 19 Engine body Cooling 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 Electrical system Description 51 Description 68 Repair instructions I mportant info 70 Oil pump 52 Starting with auxiliary battery 71 Replacing the oil filter 52 Troubleshooting, glow plug, charging system 72 Cleaning the oil channels ......................................... 52 Alternator 74 Starter motor 76 Electrical components 78 Fuel system Wiring diagram 80 Description 53 Extra equipment 87 Note!

The data given in this Workshop Manual refers in general to engines in both A, B and C versions unless otherwise stated. 1

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Safety Precautions 0 I ntroduction Check that the warning or information labels on the product are always clearly visible. Replace This Workshop Manual contains technical specifica- tions, descriptions and instructions for the repair of the Volvo Penta products or product types described in the Table of Contents. Check that you have the correct Workshop Manual for your engine. l abels which have been damaged or painted over. 0 Before starting work on the engine read the "Safety Pre- cautions", "Genera! Information" and "Repair Instruc- tion" sections of this Workshop Manual carefully. Engines with turbocharger ( TC ): Never start the engine without installing the air cleaner ( ACL ) filter.

The rotating compressor in the Turbo can cause serious personal injury. Foreign objects entering the intake ducts can also cause me- chanical damage. I mportant I n this book and on the product you will find the follow- i ng special warning symbols. Q WARNING! Possible danger of personal injury, extensive damage to property or serious me- chanical malfunction if the instructions are not followed. Never use start spray products or similar when starting the engine. They may cause an explo- sion in the inlet manifold. Danger of personal in- jury. I MPORTANT ! Used to draw your attention to something that can cause damage or malfunc- tions on a product or damage to property.

IL Avoid opening the filler cap for engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out. Open the filler cap slowly and release the pressure in the system. Take great care if a cock, plug or engine coolant line must be re- moved from a hot engine. Steam or hot coolant can spray out in any direction. Note! Used to draw your attention to important informa- tion that will facilitate the work or operation in progress. Below is a summary of the risks involved and safety precautions you should always observe or carry out when operating or servicing the engine.

0 I mmobilize the engine by turning off the power 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. Hot oil can cause burns. Avoid getting hot oil on the skin. Ensure that the lubrication system is not under pressure before carrying out any work. Never start or operate the engine with the oil fill- er cap removed, otherwise oil could be ejected. As a general rule all service operations must be carried out with the engine stopped. However, some work, for example certain adjustments re- quire that the engine is running when they are carried out.

Approaching an engine which is op- erating is a safety risk. Loose clothing or long hair can fasten in rotating parts and cause seri- ous personal injury. If working in proximity of an engine which is operating, careless 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. I& Stop the engine and close the sea cock before carrying out operations on the engine cooling system.

0 Only start the engine in a well-ventilated area. If operating the engine in an enclosed area en- sure that there is exhaust ventilation leading out of the engine compartment or workshop area to remove exhaust gases and crankcase ventila- tion emissions. 2

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O 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! Ensure that rags soaked in oil or fuel and used fuel or oil filters are stored safely. Rags soaked i n 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. 0 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. 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 - oxyhydrogen .

This gas i s 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. 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 etc .).

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. 2L 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. 0 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- IL Excercise 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 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.

A Turn the engine off and turn off the power at the main switch(es ) before carrying out work on the electrical system. i ng. 0 All fuels and many chemical substances are flammable. Do not allow naked flame or sparks Clutch adjustments must be carried out with the engine stopped. i n 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. 3

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